Sep 30, 2011 ... Ninja 250R. Motorcycle. Service Manual. All rights reserved. No parts of this
publication may be reproduced, stored in a retrieval system, or.
Ninja 250R
Motorcycle Service Manual
Quick Reference Guide
This quick reference guide will assist you in locating a desired topic or procedure. •Bend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page. •Refer to the sectional table of contents for the exact pages to locate the specific topic required.
General Information
1 j
Periodic Maintenance
2 j
Fuel System (DFI)
3 j
Cooling System
4 j
Engine Top End
5 j
Clutch
6 j
Engine Lubrication System
7 j
Engine Removal/Installation
8 j
Crankshaft/Transmission
9 j
Wheels/Tires
10 j
Final Drive
11 j
Brakes
12 j
Suspension
13 j
Steering
14 j
Frame
15 j
Electrical System
16 j
Appendix
17 j
Ninja 250R
Motorcycle Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Division/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan. No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible. The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your Motorcycle dealer for the latest information on product improvements incorporated after this publication. All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts.
© 2008 Kawasaki Heavy Industries, Ltd.
First Edition (1) : Feb. 20, 2008 (K)
LIST OF ABBREVIATIONS A ABDC AC ATDC BBDC BDC BTDC °C DC F °F ft g h L
ampere(s) after bottom dead center alternating current after top dead center before bottom dead center bottom dead center before top dead center degree(s) Celsius direct current farad(s) degree(s) Fahrenheit foot, feet gram(s) hour(s) liter(s)
lb m min N Pa PS psi r rpm TDC TIR V W Ω
pound(s) meter(s) minute(s) newton(s) pascal(s) horsepower pound(s) per square inch revolution revolution(s) per minute top dead center total indicator reading volt(s) watt(s) ohm(s)
COUNTRY AND AREA CODES AT
Austria
CH
Switzerland
DE
Germany
WVTA WVTA Model (Full Power) (FULL N) GB WVTA WVTA Model (Left Side Traffic Full (FULL N) Power)
Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may adversely affect safe operation. For the duration of the warranty period, we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty. To get the longest life out of your vehicle. Follow the Periodic Maintenance Chart in the Service Manual. Be alert for problems and non-scheduled maintenance. Use proper tools and genuine Kawasaki Motorcycle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Service Manual. Genuine parts provided as spare parts are listed in the Parts Catalog. Follow the procedures in this manual carefully. Don’t take shortcuts. Remember to keep complete records of maintenance and repair with dates and any new parts installed.
• • •
• •
How to Use This Manual In this manual, the product is divided into its major systems and these systems make up the manual’s chapters. The Quick Reference
Guide shows you all of the product’s system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents. For example, if you want ignition coil information, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chapter to find the Ignition Coil section. Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices.
WARNING This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life.
CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment. This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information.
NOTE
○This note symbol indicates points of particular interest for more efficient and convenient operation.
a procedural step or work to be • Indicates done.
○Indicates a procedural sub-step or how to do
the work of the procedural step it follows. It also precedes the text of a NOTE. Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows. In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly.
GENERAL INFORMATION 1-1
General Information Table of Contents Before Servicing ..................................................................................................................... Model Identification................................................................................................................. General Specifications............................................................................................................ Unit Conversion Table ............................................................................................................
1-2 1-7 1-8 1-11
1
1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts. Especially note the following.
Battery Ground
Before completing any service on the motorcycle, disconnect the battery cables from the battery to prevent the engine from accidentally turning over. Disconnect the ground cable (–) first and then the positive (+). When completed with the service, first connect the positive (+) cable to the positive (+) terminal of the battery then the negative (–) cable to the negative terminal.
Edges of Parts Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts.
Solvent Use a high-flush point solvent when cleaning parts. High -flush point solvent should be used according to directions of the solvent manufacturer.
Cleaning Vehicle before Disassembly Clean the vehicle thoroughly before disassembly. Dirt or other foreign materials entering into sealed areas during vehicle disassembly can cause excessive wear and decrease performance of the vehicle.
GENERAL INFORMATION 1-3 Before Servicing Arrangement and Cleaning of Removed Parts Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly.
Storage of Removed Parts After all the parts including subassembly parts have been cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly.
Inspection Reuse of worn or damaged parts may lead to serious accident. Visually inspect removed parts for corrosion, discoloration, or other damage. Refer to the appropriate sections of this manual for service limits on individual parts. Replace the parts if any damage has been found or if the part is beyond its service limit.
Replacement Parts Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.
Assembly Order In most cases assembly order is the reverse of disassembly, however, if assembly order is provided in this Service Manual, follow the procedures given.
1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quarter turn and then remove them. If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally.
Tightening Torque Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fasteners to the specified torque using a good quality torque wrench.
Force Use common sense during disassembly and assembly, excessive force can cause expensive or hard to repair damage. When necessary, remove screws that have a non -permanent locking agent applied using an impact driver. Use a plastic-faced mallet whenever tapping is necessary.
Gasket, O-ring Hardening, shrinkage, or damage of both gaskets and O-rings after disassembly can reduce sealing performance. Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains. Install the new gaskets and replace the used O-rings when re-assembling.
Liquid Gasket, Non-permanent Locking Agent For applications that require Liquid Gasket or a Non-permanent Locking Agent, clean the surfaces so that no oil residue remains before applying liquid gasket or non-permanent locking agent. Do not apply them excessively. Excessive application can clog oil passages and cause serious damage.
GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use smooth movements when installing.
Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressure on the correct bearing race as shown. Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage.
Oil Seal, Grease Seal Do not remove pressed oil or grease seals unless removal is necessary. Replace with new ones whenever removed. Press new oil seals with manufacture and size marks facing out. Make sure the seal is aligned properly when installing.
Apply specified grease to the lip of seal before installing the seal.
Circlips, Cotter Pins Replace the circlips or cotter pins that were removed with new ones. Take care not to open the clip excessively when installing to prevent deformation.
1-6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubrication points are called out throughout this manual, apply the specific oil or grease as specified.
Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (clockwise viewed from output side).
Electrical Wires A two-color wire is identified first by the primary color and then the stripe color. Unless instructed otherwise, electrical wires must be connected to those of the same color.
Instrument Use a meter that has enough accuracy for an accurate measurement. Read the manufacture’s instructions thoroughly before using the meter. Incorrect values may lead to improper adjustments.
GENERAL INFORMATION 1-7 Model Identification EX250K8F Left Side View
EX250K8F Right Side View
Frame Number
Engine Number
1-8 GENERAL INFORMATION General Specifications Items Dimensions Overall Length Overall Width Overall Height Wheelbase Road Clearance Seat Height Dry Mass Curb Mass: Front Rear Fuel Tank Capacity Performance Minimum Turning Radius Engine Type Cooling System Bore and Stroke Displacement Compression Ratio Maximum Horsepower Maximum Torque Carburetion System Starting System Ignition System Timing Advance Ignition Timing Spark Plug Cylinder Numbering Method Firing Order Valve Timing: Inlet: Open Close Duration Exhaust: Open Close Duration
EX250K8F 2 085 mm (82.09 in.) 715 mm (28.15 in.) 1 115 mm (43.90 in.) 1 400 mm (55.12 in.) 130 mm (5.12 in.) 775 mm (30.51 in.) 152 kg (335.2 lb) 82 kg (180.8 lb) 87 kg (191.8 lb) 17.8 L (4.7 US gal.) 2.7 m (8.9 ft) 4-stroke, DOHC, 2-cylinder Liquid-cooled 62.0 × 41.2 mm (2.44 × 1.62 in.) 249 cm³ (15.19 cu in.) 11.6 : 1 24 kW (33 PS) @11 000 r/min (rpm) 22 N·m (2.2 kgf·m, 16 ft·lb) @8 200 r/min (rpm) FI (Fuel Injection) KEIHIN TTK28 × 2 Electric starter Battery and coil (transistorized) Electronically advanced (digital igniter in ECU) From 10° BTDC @1 300 r/min (rpm) 38° BTDC @6 000 r/min (rpm) NGK CR8E Left to right, 1-2 1-2
36° BTDC 56° ABDC 272° 61° BBDC 31° ATDC 272°
GENERAL INFORMATION 1-9 General Specifications Items Lubrication System Engine Oil: Type Viscosity Capacity Drive Train Primary Reduction System: Type Reduction Ratio Clutch Type Transmission: Type Gear Ratios: 1st 2nd 3rd 4th 5th 6th Final Drive System: Type Reduction Ratio Overall Drive Ratio Frame Type Caster (Rake Angle) Trail Front Tire: Type Size Rim Size Rear Tire: Type Size Rim Size Front Suspension: Type Wheel Travel Rear Suspension: Type Wheel Travel
EX250K8F Forced lubrication (wet sump) API SE, SF or SG API SH, SJ or SL with JASO MA SAE 10W-40 1.7 L (1.8 US qt)
Gear 3.087 (71/23) Wet multi disc 6-speed, constant mesh, return shift 2.600 1.789 1.409 1.160 1.000 0.893
(39/15) (34/19) (31/22) (29/25) (27/27) (25/28)
Chain drive 3.071 (43/14) 8.466 @Top gear Tubular, diamond 26° 82 mm (3.23 in.) Tubeless 110/70 17 M/C (54S) 17 × 2.75 Tubeless 130/70 17 M/C (62S) 17 × 3.50 Telescopic fork 120 mm (4.72 in.) Swingarm (uni-trak) 130 mm (5.12 in.)
1-10 GENERAL INFORMATION General Specifications Items Brake Type: Front Rear Electrical Equipment Battery Headlight: Type Bulb: High Low Tail/Brake Light Alternator: Type Rated Output
EX250K8F Single disc Single disc 12 V 8 Ah Semi-sealed beam 12 V 55 W (quartz-halogen) × 2 12 V 55 W (quartz-halogen) 12 V 5/21 W Three-phase AC 23.0 A/14.0 V @5 000 r/min (rpm)
Specifications are subject to change without notice, and may not apply to every country.
GENERAL INFORMATION 1-11 Unit Conversion Table Prefixes for Units: Prefix mega kilo centi milli micro
Symbol M k c m µ
Units of Length: × × × × ×
Power 1 000 000 1 000 0.01 0.001 0.000001
Units of Mass: kg g
× ×
2.205 0.03527
= =
lb oz
Units of Volume: L L L L L L mL mL mL
× × × × × × × × ×
0.2642 0.2200 1.057 0.8799 2.113 1.816 0.03381 0.02816 0.06102
× × × ×
0.1020 0.2248 9.807 2.205
Units of Temperature:
× × ×
0.6214 3.281 0.03937
= = =
mile ft in
= = = = = =
kgf·m ft·lb in·lb N·m ft·lb in·lb
= = = = = =
kgf/cm² psi cmHg kPa psi kPa
=
mph
= = = =
PS HP kW HP
Units of Torque: N·m N·m N·m kgf·m kgf·m kgf·m
× × × × × ×
0.1020 0.7376 8.851 9.807 7.233 86.80
Units of Pressure: = = = = = = = = =
gal (US) gal (imp) qt (US) qt (imp) pint (US) pint (imp) oz (US) oz (imp) cu in
= = = =
kg lb N lb
Units of Force: N N kg kg
km m mm
kPa kPa kPa kgf/cm² kgf/cm² cmHg
× × × × × ×
0.01020 0.1450 0.7501 98.07 14.22 1.333
Units of Speed: km/h
×
0.6214
Units of Power: kW kW PS PS
× × × ×
1.360 1.341 0.7355 0.9863
PERIODIC MAINTENANCE 2-1
Periodic Maintenance Table of Contents Periodic Maintenance Chart ................................................................................................... Torque and Locking Agent...................................................................................................... Specifications ......................................................................................................................... Special Tools .......................................................................................................................... Periodic Maintenance Procedures.......................................................................................... Fuel System (DFI)................................................................................................................ Air Cleaner Element Cleaning........................................................................................... Throttle Control System Inspection................................................................................... Engine Vacuum Synchronization Inspection..................................................................... Idle Speed Inspection ....................................................................................................... Idle Speed Adjustment...................................................................................................... Fuel Hose Inspection (fuel leak, damage, installation condition) ...................................... Cooling System.................................................................................................................... Coolant Level Inspection................................................................................................... Water Hose and Pipe Inspection (coolant leak, damage, installation condition) .............. Engine Top End ................................................................................................................... Valve Clearance Inspection .............................................................................................. Valve Clearance Adjustment............................................................................................. Air Suction System Damage Inspection............................................................................ Clutch................................................................................................................................... Clutch Operation Inspection.............................................................................................. Wheels/Tires ........................................................................................................................ Air Pressure Inspection..................................................................................................... Wheel/Tire Damage Inspection......................................................................................... Tire Tread Wear Inspection............................................................................................... Wheel Bearing Damage Inspection .................................................................................. Final Drive............................................................................................................................ Drive Chain Lubrication Condition Inspection ................................................................... Drive Chain Slack Inspection ............................................................................................ Drive Chain Slack Adjustment .......................................................................................... Wheel Alignment Inspection ............................................................................................. Drive Chain Wear Inspection ............................................................................................ Chain Guide Wear Inspection ........................................................................................... Brakes.................................................................................................................................. Brake Fluid Leak (Brake Hose and Pipe) Inspection ........................................................ Brake Hose and Pipe Damage and Installation Condition Inspection............................... Brake Fluid Level Inspection............................................................................................. Brake Pad Wear Inspection .............................................................................................. Brake Operation Inspection .............................................................................................. Brake Light Switch Operation Inspection .......................................................................... Suspension .......................................................................................................................... Front Forks/Rear Shock Absorber Operation Inspection .................................................. Front Fork Oil Leak Inspection.......................................................................................... Rear Shock Absorber Oil Leak Inspection ........................................................................ Rocker Arm Operation Inspection..................................................................................... Tie-Rod Operation Inspection ........................................................................................... Swingarm Pivot Lubrication .............................................................................................. Steering ............................................................................................................................... Steering Play Inspection ................................................................................................... Steering Play Adjustment..................................................................................................
2-3 2-6 2-11 2-13 2-14 2-14 2-14 2-14 2-15 2-18 2-18 2-18 2-19 2-19 2-20 2-20 2-20 2-21 2-23 2-23 2-23 2-24 2-24 2-25 2-25 2-26 2-26 2-26 2-27 2-27 2-28 2-29 2-29 2-30 2-30 2-30 2-30 2-31 2-31 2-32 2-32 2-32 2-33 2-33 2-33 2-33 2-34 2-34 2-34 2-35
2
2-2 PERIODIC MAINTENANCE Steering Stem Bearing Lubrication ................................................................................... Electrical System ................................................................................................................. Lights and Switches Operation Inspection........................................................................ Headlight Aiming Inspection ............................................................................................. Sidestand Switch Operation Inspection ............................................................................ Engine Stop Switch Operation Inspection......................................................................... Others .................................................................................................................................. Chassis Parts Lubrication ................................................................................................. Bolts, Nuts and Fasteners Tightness Inspection............................................................... Replacement Parts .............................................................................................................. Air Cleaner Element Replacement.................................................................................... Fuel Hose Replacement ................................................................................................... Coolant Change ................................................................................................................ Radiator Hose and O-ring Replacement........................................................................... Engine Oil Change............................................................................................................ Oil Filter Replacement ...................................................................................................... Brake Hose and Pipe Replacement.................................................................................. Brake Fluid Change .......................................................................................................... Master Cylinder Rubber Parts Replacement .................................................................... Caliper Rubber Parts Replacement .................................................................................. Spark Plug Replacement ..................................................................................................
2-35 2-36 2-36 2-38 2-39 2-40 2-40 2-40 2-42 2-43 2-43 2-44 2-45 2-48 2-48 2-49 2-50 2-50 2-51 2-53 2-54
PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected.
Periodic Inspection FREQUENCY Whichever comes first
* ODOMETER READING × 1 000 km (× 1 000 mile) 1
ITEM Fuel System
Every
year
Fuel leak (fuel hose and pipe) - inspect
year
Fuel hose and pipe damage - inspect
year
Fuel hose and pipe installation condition inspect Cooling System
year
Coolant level - inspect Coolant leak (water hose and pipe) - inspect
year
Water hose damage - inspect
year
Water hose installation condition - inspect
year
Engine Top End
Wheel/tire damage - inspect Tire tread wear, abnormal wear - inspect Wheel bearing damage - inspect
year
Final Drive Drive chain lubrication condition - inspect # Drive chain slack - inspect #
• • • • • • • •
• • • •
• • • •
• • • •
2-19
• •
• •
• •
2-20
•
•
•
2-23
• • • •
• • • •
• • • •
2-24
•
Every 600 km (400 mile) Every 1 000 km (600 mile)
• •
Drive chain wear - inspect # Chain guide wear - inspect Brakes Brake fluid leak (brake hose and pipe) inspect
36
2-14
• year
30
• • • • • • •
Air suction system damage - inspect
Tire air pressure - inspect
24
• • • • • • •
Valve clearance - inspect Clutch Clutch operation (play, disengagement, engagement) - inspect Wheels and Tires
18
• • • • • • •
Engine vacuum synchronization - inspect Idle speed - inspect
12
(0.6) (4) (7.5) (12) (15) (20) (24)
Air cleaner element - clean Throttle control system (play, smooth return, no drag) - inspect
6
year
Brake hose and pipe damage - inspect
year
Brake hose installation condition - inspect
year
See Page
• •
2-14 2-15 2-18 2-18 2-18 2-18
2-20 2-20 2-20
2-23
2-25 2-25 2-26 2-26 2-27
• •
2-29
• • • • • • • • • • • • • • • • • • • • •
2-30
2-29
2-30 2-30
2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Whichever comes first
* ODOMETER READING × 1 000 km (× 1 000 mile) 1
ITEM Brake fluid level - inspect
year
Brake light switch operation - inspect Suspension Front forks/rear shock absorber operation (damping and smooth stroke) - inspect Front forks/rear shock absorber oil leak inspect
12
• • • • • • •
year
Rocker arm operation - inspect Tie-rods operation - inspect Swingarm pivot - lubricate
• • • •
Steering stem bearings - lubricate
year 2 years
Lights and switches operation - inspect
year
Headlight aiming - inspect
year
Sidestand switch operation - inspect
year
Engine stop switch operation - inspect
year
•
Others Bolts and nuts tightness - inspect
30
36
year
•
• • • •
• • • •
• • • •
• • • •
2-30 2-31 2-31 2-32
• • • • •
• • • •
2-32
•
• •
•
2-34
• • • •
• • • •
• • • •
2-36
• •
• •
• •
2-40
Electrical System
Chassis parts - lubricate
24
• • • •
Steering Steering play - inspect
18
Every (0.6) (4) (7.5) (12) (15) (20) (24) 6 months
Brake pad wear - inspect # Brake operation (effectiveness, play, no drag) - inspect
6
See Page
2-33 2-33 2-33 2-34
2-35
2-38 2-39 2-40
2-42
#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or frequent starting/stopping. *: For higher odometer readings, repeat at the frequency interval established here.
PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY Whichever comes first
* ODOMETER READING × 1 000 km (× 1 000 mile) 1
ITEM Air cleaner element # - replace
Every 2 years
Fuel hose - replace
4 years
Coolant - change
3 years
Radiator hose and O-ring - replace
3 years
Engine oil # - change
year
Oil filter - replace
year
Brake hose and pipe - replace
4 years
Brake fluid - change
2 years
Rubber parts of master cylinder and caliper replace
4 years
Spark plug - replace
12
24
(0.6) (7.5) (15)
36
48
(24)
(30)
See Page
2-43
• •
• •
• •
• • • •
• •
•
•
•
2-44 2-45 2-48
• • • • • •
2-48 2-49 2-50 2-50 2-51, 2-53 2-54
#: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed or frequent starting/stopping. *: For higher odometer readings, repeat at the frequency interval established here.
2-6 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in the "Remarks" column mean: G: Apply grease. L: Apply a non-permanent locking agent. MO: Apply molybdenum disulfide grease oil solution. (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1) S: Follow the specified tightening sequence. Si: Apply silicone grease (ex. PBC grease). SS: Apply silicone sealant.
Fastener Fuel System (DFI) Air Cleaner Housing Cap Bolts Air Cleaner Housing Mounting Bolts Air Cleaner Housing Screws Air Duct Clamp Screws Crankshaft Sensor Screws Delivery Pipe Assy Mounting Screws Fuel Pump Bolts Inlet Air Temperature Sensor Screw Oxygen Sensor Speed Sensor Bolt Throttle Body Assy Holder Clamp Screws Water Temperature Sensor Cooling System Coolant Drain Bolt (Cylinder) Coolant Drain Bolt (Water Pump) Radiator Bolts Radiator Cap Bracket Bolt Radiator (Water) Hose Clamp Screws Reserve Tank Bolts Reserve Tank Bracket Bolts Reserve Tank Cap Resistor Bolt Thermostat Cover Bolts Thermostat Housing Mounting Bolts Water Hose Fitting Bolts Water Pipe Bolts Water Pump Bolts Water Pump Cover Bolts Water Temperature Sensor Engine Top End Air Suction Valve Cover Bolts
N·m
Torque kgf·m
ft·lb
2.5 9.8 1.15 2.0 3.0 3.4 9.8 1.2 44.1 7.8 2.0 25
0.25 1.0 0.12 0.20 0.31 0.35 1.0 0.12 4.50 0.80 0.20 2.5
22 in·lb 87 in·lb 10 in·lb 18 in·lb 27 in·lb 30 in·lb 87 in·lb 11 in·lb 32.5 69 in·lb 18 in·lb 18
5.9 9.8 9.8 9.8 1.5 9.8 9.8 –
0.60 1.0 1.0 1.0 0.15 1.0 1.0 –
52 87 87 87 13 87 87
7.8 9.8 9.8 9.8 9.8 9.8 9.8 25
0.80 1.0 1.0 1.0 1.0 1.0 1.0 2.5
69 in·lb 87 in·lb 87 in·lb 87 in·lb 87 in·lb 87 in·lb 87 in·lb 18
9.8
1.0
87 in·lb
in·lb in·lb in·lb in·lb in·lb in·lb in·lb –
Remarks
L
L
Hand -Tighten
PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Fastener Air Switching Valve Bracket Bolts Camshaft Cap Bolts Camshaft Chain Tensioner Cap Bolt Camshaft Chain Tensioner Mounting Bolts Camshaft Sprocket Bolts Coolant Drain Bolt (Cylinder) Cylinder Head Bolts (M8) Cylinder Head Bolt (M6) Cylinder Head Cover Bolts Cylinder Head Jacket Plugs Exhaust Pipe Holder Nuts Exhaust Pipe Mounting Bolt Muffler Body Clamp Bolt Muffler Body Mounting Bolt Muffler Body Rear Cover Bolts Muffler Cover Bolts Muffler Cover Clamp Bolt Muffler Cover Clamp Screw Rear Camshaft Chain Guide Bolt Spark Plugs Throttle Body Assy Holder Clamp Screws Clutch Clutch Cover Bolts Clutch Hub Nut Clutch Lever Clamp Bolt Clutch Spring Bolts Oil Filler Plug Engine Lubrication System Crankcase Oil Passage Plug Engine Oil Drain Bolt (Crankcase) Engine Oil Drain Bolt (Oil Screen Cover) Oil Breather Mounting Bolts Oil Filter Mounting Bolt Oil Hose Banjo Bolts Oil Passage Plugs Oil Pipe Banjo Bolt Oil Pressure Relief Valve Oil Pressure Switch Oil Pressure Switch Terminal Bolt Oil Pump Mounting Bolts Oil Screen Cover Bolts
N·m 9.8 12 5.0 9.8 15 5.9 31.4 12 9.8 20 12 9.8 17 30 9.8 9.8 9.8 6.9 17 13 2.0
Torque kgf·m 1.0 1.2 0.51 1.0 1.5 0.60 3.2 1.2 1.0 2.0 1.2 1.0 1.7 3.1 1.0 1.0 1.0 0.70 1.7 1.3 0.20
ft·lb 87 in·lb 106 in·lb 44 in·lb 87 in·lb 11 52 in·lb 23.2 106 in·lb 87 in·lb 15 106 in·lb 87 in·lb 13 22 87 in·lb 87 in·lb 87 in·lb 61 in·lb 13 115 in·lb 18 in·lb
9.8 132 8.8 8.8 –
1.0 13.5 0.90 0.90 –
87 in·lb 97.4 78 in·lb 78 in·lb –
15 19.6 19.6 9.8 19.6 19.6 20 12 15 15 1.5 9.8 9.8
1.5 2.0 2.0 1.0 2.0 2.0 2.0 1.2 1.5 1.5 0.15 1.0 1.0
11 14.5 14.5 87 in·lb 14.5 14.5 15 106 in·lb 11 11 13 in·lb 87 in·lb 87 in·lb
Remarks
S
L MO, S S L
L
Hand -Tighten
L
L L SS G L
2-8 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Engine Removal/Installation Engine Mounting Bracket Bolts and Nuts Engine Mounting Nuts Crankshaft/Transmission Connecting Rod Big End Nuts Crankcase Bolts (M8, L = 90 mm) Crankcase Bolts (M8, L = 73 mm) Crankcase Bolts (M6) Neutral Switch Oil Breather Mounting Bolts Shift Drum Bearing Holder Bolts Shift Drum Pin Plate Bolt Shift Drum Positioning Bolt Shift Lever Bolt Shift Pedal Mounting Bolt Shift Shaft Return Spring Pin Starter Motor Clutch Bolts Tie-Rod Locknuts Wheels/Tires Front Axle Nut Rear Axle Nut Final Drive Engine Sprocket Cover Bolts Engine Sprocket Nut Rear Axle Nut Rear Sprocket Nuts Speed Sensor Mounting Bracket Bolts Brakes Bleed Valves Brake Hose Banjo Bolts Brake Lever Pivot Bolt Brake Lever Pivot Bolt Locknut Brake Pedal Bolt Front Brake Disc Mounting Bolts Front Brake Light Switch Screw Front Brake Pad Pins Front Brake Reservoir Cap Screws Front Caliper Holder Pin Bolt Front Caliper Mounting Bolts Front Master Cylinder Clamp Bolts Rear Brake Disc Mounting Bolts Rear Brake Pad Pins Rear Caliper Holder Pin Bolt
N·m
Torque kgf·m
ft·lb
69 69
7.0 7.0
51 51
27.5 24 19 12 15 9.8 12 9.0 24.5 12 25 19.6 34.3 7.0
2.8 2.4 1.9 1.2 1.5 1.0 1.2 0.92 2.5 1.2 2.5 2.0 3.5 0.71
20 18 14 106 in·lb 11 87 in·lb 106 in·lb 80 in·lb 18 106 in·lb 18 14.5 25 62 in·lb
88 98
9.0 10.0
65 72.3
9.8 127 98 59 9.8
1.0 13.0 10.0 6.0 1.0
87 in·lb 93.7 72.3 44 87 in·lb
5.5 25 5.9 5.9 8.8 27 1.2 17.2 1.5 17.2 25 8.8 27 17.2 17.2
0.56 2.5 0.60 0.60 0.90 2.8 0.12 1.8 0.15 1.8 2.5 0.90 2.8 1.8 1.8
49 in·lb 18 52 in·lb 52 in·lb 78 in·lb 20 11 in·lb 13 13 in·lb 13 18 78 in·lb 20 13 13
Remarks
MO MO, S MO, S
L L L
L L
MO
L L Si
L
Si S L Si
PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Fastener Rear Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Rear Master Cylinder Push Rod Locknut Suspension Front Fork Bottom Allen Bolts Lower Front Fork Clamp Bolts Rear Shock Absorber Nuts Swingarm Pivot Shaft Nut Tie-Rod Nuts Uni-Trak Rocker Arm Nut Upper Front Fork Clamp Bolts Steering Handlebar Mounting Bolts Lower Front Fork Clamp Bolts Steering Stem Head Bolt Steering Stem Nut Switch Housing Screws Upper Front Fork Clamp Bolts Frame Front Footpeg Bracket Bolts Rear Footpeg Bracket Bolts Sidestand Nut Sidestand Switch Bolt Windshield Mounting Bolts Electrical System Alternator Cover Bolts Alternator Rotor Bolt Crankshaft Sensor Screws Front Brake Light Switch Screw Fuel Pump Bolts License Plate Light Cover Screws License Plate Light Mounting Screws Neutral Switch Oil Pressure Switch Oil Pressure Switch Terminal Bolt Oxygen Sensor Plugs (Alternator Cover) Regulator/Rectifier Bolts Resistor Bolt Sidestand Switch Bolt Spark Plugs Speed Sensor Bolt
N·m 25 25 17.2
Torque kgf·m 2.5 2.5 1.8
ft·lb 18 18 13
20 30 59 98 59 59 20
2.0 3.1 6.0 10.0 6.0 6.0 2.0
15 22 44 72.3 44 44 15
25 30 44 4.9 3.5 20
2.5 3.1 4.5 0.50 0.36 2.0
18 22 32 43 in·lb 31 in·lb 15
25 25 39 8.8 0.42
2.5 2.5 4.0 0.90 0.043
18 18 29 78 in·lb 3.7 in·lb
9.8 88.2 3.0 1.2 9.8 0.90 1.2 15 15 1.5 44.1 –
1.0 9.0 0.31 0.12 1.0 0.092 0.12 1.5 1.5 0.15 4.50 –
87 in·lb 65 27 in·lb 11 in·lb 87 in·lb 8.0 in·lb 11 in·lb 11 11 13 in·lb 32.5 –
9.8 7.8 8.8 13 7.8
1.0 0.80 0.90 1.3 0.80
87 in·lb 69 in·lb 78 in·lb 115 in·lb 69 in·lb
Remarks
L
L
S
L
SS G Hand -Tighten
L L
2-10 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Starter Motor Cable Terminal Nut Starter Motor Clutch Bolts Starter Motor Mounting Bolts Starter Motor Terminal Locknut Starter Motor Through Bolts Starter Relay Cable Terminal Nuts Stator Coil Bolts Switch Housing Screws Tail/Brake Light Mounting Bolts Water Temperature Sensor
N·m 9.8 34.3 9.8 6.9 3.4 5.0 12 3.5 5.9 25
Torque kgf·m 1.0 3.5 1.0 0.70 0.35 0.51 1.2 0.36 0.60 2.5
ft·lb 87 in·lb 25 87 in·lb 61 in·lb 30 in·lb 44 in·lb 106 in·lb 31 in·lb 52 in·lb 18
Remarks
L
The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads.
Basic Torque for General Fasteners Threads Diameter (mm) 5 6 8 10 12 14 16 18 20
N·m 3.4 ∼ 4.9 5.9 ∼ 7.8 14 ∼ 19 25 ∼ 34 44 ∼ 61 73 ∼ 98 115 ∼ 155 165 ∼ 225 225 ∼ 325
Torque kgf·m 0.35 ∼ 0.50 0.60 ∼ 0.80 1.4 ∼ 1.9 2.6 ∼ 3.5 4.5 ∼ 6.2 7.4 ∼ 10.0 11.5 ∼ 16.0 17.0 ∼ 23.0 23.0 ∼ 33.0
ft·lb 30 ∼ 43 in·lb 52 ∼ 69 in·lb 10.0 ∼ 13.5 19.0 ∼ 25 33 ∼ 45 54 ∼ 72 83 ∼ 115 125 ∼ 165 165 ∼ 240
PERIODIC MAINTENANCE 2-11 Specifications Item Fuel System (DFI) Throttle Grip Free Play Idle Speed Throttle Body Vacuum
Standard
Service Limit
– – – 2 ∼ 3 mm (0.08 ∼ 0.12 in.) 1 300 ±50 r/min (rpm) – – – 24.0 ±1.33 kPa (180 ±10 mmHg) at idle – – – speed Bypass Screws (Turn Out) 0 ∼ 2 1/2 (for reference) – – – Air Cleaner Element Polyurethane foam – – – Cooling System Coolant: Type (Recommended) Permanent type of antifreeze – – – – – – Color Green Mixed Ratio Soft water 50%, Coolant 50% – – – Freezing Point –35°C (–31°F) – – – Total Amount 1.5 L (1.6 US qt) – – – Engine Top End Valve Clearance: Exhaust 0.22 ∼ 0.29 mm (0.0087 ∼ 0.0114 in.) – – – Inlet 0.15 ∼ 0.24 mm (0.0059 ∼ 0.0094 in.) – – – Clutch – – – Clutch Lever Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Engine Lubrication System Engine Oil: Type API SE, SF or SG – – – API SH, SJ or SL with JASO MA Viscosity SAE 10W-40 – – – Capacity 1.3 L (1.4 US qt) (when filter is not – – – removed) 1.6 L (1.7 US qt) (when filter is removed) – – – 1.7 L (1.8 US qt) (when engine is – – – completely dry) Level Between upper and lower level lines – – – (Wait 2 ∼ 3 minutes after idling or running) Wheels/Tires Tread Depth: Front: IRC 4.2 mm (0.17 in.) 1 mm (0.04 in.), (AT, CH, DE) BRIDGESTONE 4.6 mm (0.18 in.) 1.6 mm (0.06 in.) DUNLOP 4.5 mm (0.18 in.) Rear: IRC 6.5 mm (0.26 in.) Up to 130 km/h (80 mph): 2 mm (0.08 in.), BRIDGESTONE 7.0 mm (0.28 in.) Over 130 km/h (80 mph): DUNLOP 7.4 mm (0.29 in.) 3 mm (0.12 in.)
2-12 PERIODIC MAINTENANCE Specifications Item Air Pressure (when Cold): Front Rear Final Drive Drive Chain Slack Drive Chain Wear (20-link Length) Standard Chain: Make Type Link Brakes Brake Fluid: Grade Brake Pad Lining Thickness: Front Rear Brake Light Timing: Front Rear Electrical System Spark Plug: Type Gap
Standard Up to 170 kg (375 lb) load: 200 kPa (2.00 kgf/cm², 28 psi) Up to 170 kg (375 lb) load: 225 kPa (2.25 kgf/cm², 32 psi) 20 ∼ 30 mm (0.8 ∼ 1.2 in.) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.)
Service Limit – – – – – –
– – – 323 mm (12.7 in.)
ENUMA EK520SR-O2 106 links
– – – – – – – – –
DOT4
– – –
4.5 mm (0.18 in.) 4.5 mm (0.18 in.)
1 mm (0.04 in.) 1 mm (0.04 in.)
Pulled ON ON after about 10 mm (0.39 in.) of pedal travel
– – – – – –
NGK CR8E 0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.)
– – – – – –
PERIODIC MAINTENANCE 2-13 Special Tools Inside Circlip Pliers: 57001-143
Filler Cap Driver: 57001-1454
Steering Stem Nut Wrench: 57001-1100
Throttle Sensor Setting Adapter: 57001-1538
Jack: 57001-1238
Extension Tube: 57001-1578
Vacuum Gauge: 57001-1369
Jack Attachment: 57001-1608
2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System (DFI) Air Cleaner Element Cleaning NOTE
○In dusty areas, the element should be cleaned more frequently than the recommended interval.
○After riding through rain or on muddily roads, the element should be cleaned immediately.
WARNING If dirt or dust is allowed to pass through into the throttle body assy, the throttle may become stuck, possibly causing accident.
CAUTION If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur. the element [A] (see Air Cleaner Element Re• Remove placement).
WARNING Clean the element in a well-ventilated area, and make sure that there are no sparks or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or a low-flash point solvent to clean the element. the element in a bath of high-flash point solvent, • Clean and then dry it with compressed air or by shaking it. cleaning, saturate a clean, lint-free towel with SE, • After SF, or SG class SAE 30 oil and apply the oil to the element
• •
by tapping the element outside with the towel. Visually check the element for tears or breaks. If the element has any tears or breaks, replace the element.
Throttle Control System Inspection
that the throttle grip [A] moves smoothly from full • Check open to close, and the throttle closes quickly and com-
•
pletely by the return spring in all steering positions. If the throttle grip does not return properly, check the throttle cable routing, grip free play, and cable damage. Then lubricate the throttle cable. Check the throttle grip free play [B]. Throttle Grip Free Play Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)
PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures
• • •
• • • •
If the free play is incorrect, adjust the throttle cable as follows. Loosen the locknut [A]. Turn the adjuster [B] until the proper amount of free play can be obtained. Tighten the locknut against the adjuster securely.
If the throttle grip free play can not be adjusted with the adjuster, use the adjusters in the lower ends of the throttle cables. Remove: Left Side Cover (see Side Cover Removal in the Frame chapter) Left Lower Fairing (see Lower Fairing Removal in the Frame chapter) Turn out both upper nuts [A] and turn in both lower nuts [B] as far as they will go so as to give the throttle grip plenty of play. With the throttle grip completely closed, turn out the lower nut and turn in the upper nut of the decelerator cable [C] until the inner cable just becomes tight. Turn out the lower nut and turn in the upper nut of the accelerator cable [D] until the correct free play is obtained.
that the throttle linkage lever [A] stops against the • Check adjusting screw [B] with the throttle grip closed.
Engine Vacuum Synchronization Inspection NOTE
○These procedures are explained on the assumption that
the inlet and exhaust systems of the engine are in good condition.
the motorcycle so that it is vertical. • Situate Remove the fuel tank (see Fuel Tank Removal in the Fuel • System (DFI) chapter). off the rubber caps [A] from the fittings of each throttle • Pull body.
2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures off the air switching valve hose [A] from the air cleaner • Pull housing. the air switching valve hose end and air cleaner • Plug housing fitting.
a vacuum gauge (special tool) and hoses [A] to • Connect the fittings on the throttle body. Special Tool - Vacuum Gauge: 57001-1369
a highly accurate tachometer [B] to one of the • Connect stick coil primary leads.
the fuel hose (see Fuel Hose Replacement). • Remove Connect the following parts temporary. • Fuel Pump Lead Connector [A] Extension Tube [B] Special Tool - Extension Tube: 57001-1578
the engine and warm it up thoroughly. • Start Check • [A]. the idle speed, using a highly accurate tachometer Idle Speed Standard:
1 300 ±50 r/min (rpm)
If the idle speed is out of the specified range, adjust it with the adjusting screw (see Idle Speed Adjustment).
CAUTION Do not measure the idle speed by the tachometer of the meter unit. idling the engine, inspect the throttle body vacuum, • While using the vacuum gauge [B]. Throttle Body Vacuum Standard: 24.0 ±1.33 kPa (180 ±10 mmHg) at idle speed
If any one vacuum is not within the specification, turn in the bypass screws until it seats fully but not tightly.
CAUTION Do not over tighten them. They could be damaged, requiring replacement.
PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures out the bypass screw of the higher vacuum between • Turn #1 [A] and #2 [B] to the lower vacuum. and close the throttle valves after each measure• Open ment and adjust the idle speed as necessary. the vacuums as before. • Inspect If both vacuums are within the specification, finish the engine vacuum synchronization. If any vacuum can not be adjusted within the specification, remove the bypass screws #1, #2 and clean them.
• Remove: Bypass Screw [A] • • •
Spring [B] Washer [C] O-ring [D] Check the bypass screw and its hole for carbon deposits. If any carbons accumulate, wipe the carbons off from the bypass screw and the hole, using a cotton pad penetrated with a high-flash point solvent. Replace the O-ring with a new one. Check the tapered portion [E] of the bypass screw for wear or damage. If the bypass screw is worn or damaged, replace it. Turn in the bypass screw until it seats fully but not tightly.
• the same procedure for other bypass screw. • Repeat the synchronization. • Repeat If the vacuums are correct, check the output voltage of the main throttle sensor (see Main Throttle Sensor Output Voltage Inspection in the Fuel System (DFI) chapter). Special Tool - Throttle Sensor Setting Adapter: -1538
57001
Main Throttle Sensor Output Voltage Connections to Adapter: Digital Meter (+) → R (sensor Y/W) lead Digital Meter (–) → W (sensor BR/BK) lead Standard:
•
DC 1.020 ∼ 1.050 V at idle throttle opening
If the output voltage is out of the standard, check the input voltage of the main throttle sensor (see Main Throttle Sensor Input Voltage Inspection in the Fuel System (DFI) chapter). Remove the vacuum gauge hoses and install the rubber caps on the original position.
2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures Idle Speed Inspection
the engine and warm it up thoroughly. • Start With the • [A]. engine idling, turn the handlebar to both sides If handlebar movement changes the idle speed, the throttle cables may be improperly adjusted or incorrectly routed or damaged. Be sure to correct any of these conditions before riding (see Throttle Control System Inspection and Cable, Wire, and Hose Routing section in the Appendix chapter).
WARNING Operation with improperly adjusted, incorrectly routed or damaged cables could result in an unsafe riding condition.
• Check the idle speed. Idle Speed Standard:
1 300 ±50 r/min (rpm)
If the idle speed is out of the specified range, adjust it.
Idle Speed Adjustment
the engine and warm it up thoroughly. • Start Turn the screw [A] until the idle speed is correct. •○Open andadjusting close the throttle a few times to make sure that the idle speed is within the specified range. Readjust if necessary.
Fuel Hose Inspection (fuel leak, damage, installation condition)
○If the motorcycle is not properly handled, the high pres-
sure inside the fuel line can cause fuel to leak [A] or the hose to burst. Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) and check the fuel hose. Replace the hose if any fraying, cracks [B] or bulges [C] are noticed.
that the hose is routed according to Cable, Wire, • Check and Hose Routing section in the Appendix chapter. Replace the hose if it has been sharply bent or kinked. Hose Joints [A] Fuel Hose [B]
PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures that the hose joints are securely connected. •○Check Push and pull [A] the hose joint [B] back and forth more than two times, and make sure it is locked and does not come off. Fuel Pump Side [C] Throttle Body Assy Side [D]
WARNING Make sure the hose joint is installed correctly on the fuel supply pipe or the fuel could leak. If it comes off, reinstall the hose joint.
Cooling System Coolant Level Inspection NOTE
○Check the level when the engine is cold (room or ambient temperature).
the coolant level in the reserve tank [A] with the • Check motorcycle held perpendicular (Do not use the sidestand.). If the coolant level is lower than the "L" level line [B], unscrew the reserve tank cap and add coolant to the "F" level line [C]. "L": low "F": full
CAUTION For refilling, add the specified mixture of coolant and soft water. Adding water alone dilutes the coolant and degrades its anticorrosion properties. The diluted coolant can attack the aluminum engine parts. In an emergency, soft water alone can be added. But the diluted coolant must be returned to the correct mixture ratio within a few days. If coolant must be added often or the reserve tank has run completely dry, there is probably leakage in the cooling system. Check the system for leaks. Coolant ruins painted surfaces. Immediately wash away any coolant that spills on the frame, engine, wheels or other painted parts.
2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures Water Hose and Pipe Inspection (coolant leak, damage, installation condition)
○The high pressure inside
• •
the radiator hose can cause coolant to leak [A] or the hose to burst if the line is not properly maintained. Visually inspect the hoses for signs of deterioration. Squeeze the hoses. A hose should not be hard and brittle, nor should it be soft or swollen. Replace the hose if any fraying, cracks [B] or bulges [C] are noticed. Check that the hoses are securely connected and clamps are tightened correctly. Torque - Radiator (Water) Hose Clamp Screws: 1.5 N·m (0.15 kgf·m, 13 in·lb)
Engine Top End Valve Clearance Inspection NOTE
○Valve clearance must be checked and adjusted when the engine is cold (at room temperature).
• Remove: Cylinder Head Cover (see Cylinder Head Cover Removal in the Engine Top End chapter) Plugs [A] [B] Special Tool - Filler Cap Driver: 57001-1454
the valve clearance when the pistons are at TDC. •○Check The pistons are numbered beginning with the engine left
•
side. Using a wrench on the alternator rotor bolt, turn the crankshaft counterclockwise until the "2T" mark [A] on the alternator rotor is aligned with the projection [B] in the inspection window on the alternator cover.
○Measure the valve clearance of the valves for which the cam [A] are turned away from each other.
PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures the thickness gauge [A], measure the valve clear• Using ance between the cam and the valve lifter. Valve Clearance Standard: Exhaust 0.22 ∼ 0.29 mm (0.0087 ∼ 0.0114 in.) Inlet
0.15 ∼ 0.24 mm (0.0059 ∼ 0.0094 in.)
○Each piston has two inlet and two exhaust valves.
Measure these two inlet or exhaust valves at the same crankshaft position. Valve Clearance Measuring Position #1 Piston TDC at End of Compression Stroke: Inlet Valve Clearances of #1 Piston Exhaust Valve Clearances of #1 Piston
○Check
NOTE
the valve clearance using this method only. Checking the clearance at any other cam position may result in improper valve clearance.
Valve Clearance Measuring Position #2 Piston TDC at End of Compression Stroke: Inlet Valve Clearances of #2 Piston Exhaust Valve Clearances of #2 Piston
If the valve clearance is not within the specified range, first record the clearance, and then adjust it.
Valve Clearance Adjustment
change the valve clearance, remove the camshaft • To chain tensioner, camshafts and valve lifters. Replace the shim with one of a different thickness.
NOTE
○Mark and record the locations of the valve lifters and shims so that they can be reinstalled in their original positions.
the shim to remove any dust or oil. • Clean Measure the thickness of the removed shim [A]. • Select a new • a + b – c = dshim thickness calculation as follows. [a] Present Shim Thickness [b] Measured Valve Clearance [c] Specified Valve Clearance (Mean Value = 0.255 mm (Exhaust), 0.195 mm (Inlet)) [d] Replace Shim Thickness Example (Inlet): 2.90 + 0.45 – 0.195 = 3.155 mm
○Exchange the shim for the 3.175 size shim.
2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Adjustment Shims Thickness
Part Number
Mark
2.50
92180-1014
50
2.55
92180-1016
55
2.60
92180-1018
60
2.65
92180-1020
65
2.675
92180-1174
68
2.70
92180-1022
70
2.725
92180-1175
73
2.75
92180-1024
75
2.775
92180-1176
78
2.80
92180-1026
80
2.825
92180-1177
83
2.85
92180-1028
85
2.875
92180-1178
88
2.90
92180-1030
90
2.925
92180-1179
93
2.95
92180-1032
95
2.975
92180-1180
98
3.00
92180-1034
00
3.025
92180-1181
03
3.05
92180-1036
05
3.075
92180-1182
08
3.10
92180-1038
10
3.125
92180-1183
13
3.15
92180-1040
15
3.175
92180-1184
18
3.20
92180-1042
20
3.25
92180-1044
25
3.30
92180-1046
30
3.35
92180-1048
35
3.40
92180-1050
40
3.45
92180-1052
45
3.50
92180-1054
50
PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures CAUTION Be sure to remeasure the clearance after selecting a shim. If the clearance is out of the specified range, use the additional shim.
○If there is no valve clearance, use a shim that is a few
•
sizes smaller, and remeasure the valve clearance. When installing the shim, face the marked side toward the valve lifter. At this time, apply engine oil to the shim or the valve lifter to keep the shim in place during camshaft installation.
CAUTION Do not put shim stock under the shim. This may cause the shim to pop out at high rpm, causing extensive engine damage. Do not grind the shim. This may cause it to fracture, causing extensive engine damage. molybdenum disulfide oil solution to the valve lifter • Apply surface and install the lifter. the camshaft (see Camshaft Installation in the En• Install gine Top End chapter). the valve clearance and readjust if necessary. • Recheck • Install the removed parts (see appropriate chapters).
Air Suction System Damage Inspection
• Remove: Lower Fairings (see Lower Fairing Removal in the Frame • • •
chapter) Fuel Tank Bolts (see Fuel Tank Removal in the Fuel System (DFI) chapter) Pull the air switching valve hose [A] out of the air cleaner housing. Start the engine and run it at idle speed. Plug the air switching valve hose end with your finger and feel vacuum pulsing in the hose. If there is no vacuum pulsation, check the hose line for leak. If there is no leak, check the air switching valve (see Air Switching Valve Unit Test in the Electrical System chapter) or air suction valve (see Air Suction Valve Inspection in the Engine Top End chapter).
Clutch Clutch Operation Inspection
the clutch lever just enough to take up the free play • Pull [A]. the gap between the lever and the lever holder. • Measure If the gap is too wide, the clutch may not release fully. If the gap is too narrow, the clutch may not engage fully. In either case, adjust it. Clutch Lever Free Play Standard: 2 ∼ 3 mm (0.08 ∼ 0.12 in.)
2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures WARNING To avoid a serious burn, never touch the engine or exhaust pipe during clutch adjustment. the adjuster [A] so that 5 ∼ 6 mm (0.20 ∼ 0.24 in.) [B] • Turn of threads are visible.
the right lower fairing (see Lower Fairing Re• Remove moval in the Frame chapter). the dust cover [A] at the clutch cable lower end out • Slide of place. both adjusting nuts [B] at the clutch cover as far • Loosen as they will go. the clutch outer cable [C] tight and tighten the adjust• Pull ing nuts against the cable holder [D]. the dust cover back onto place. • Slip Turn the adjuster at the clutch lever until the free play is • correct.
WARNING Be sure that the outer cable end at the clutch lever is fully seated in the adjuster at the clutch lever, or it could slip into place later, creating enough cable play to prevent clutch disengagement. the adjustment, start the engine and check that the • After clutch does not slip and that it releases properly.
Wheels/Tires Air Pressure Inspection
the air valve cap. • Remove Measure tire air pressure with an air pressure gauge • [A] when the the tires are cold (that is, when the motorcycle
•
has not been ridden more than a mile during the past 3 hours). Install the air valve cap. Adjust the tire air pressure according to the specifications if necessary.
Air Pressure (when Cold) Front: Up to 170 kg (375 lb) load: 200 kPa (2.00 kgf/cm², 28 psi) Rear:
Up to 170 kg (375 lb) load: 225 kPa (2.25 kgf/cm², 32 psi)
PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures Wheel/Tire Damage Inspection
any imbedded stones [A] or other foreign parti• Remove cles [B] from tread. inspect the tire for cracks and cuts, and replace • Visually the tire if necessary. Swelling or high spots indicate inter-
•
nal damage, requiring tire replacement. Visually inspect the wheel for cracks, cuts and dents damage. If any damage is found, replace the wheel if necessary.
Tire Tread Wear Inspection As the tire tread wears down, the tire becomes more susceptible to puncture and failure. An accepted estimate is that 90% of all tire failures occur during the last 10% of tread life (90% worn). So it is false economy and unsafe to use the tires until they are bald. Measure the tread depth at the center of the tread with a depth gauge [A]. Since the tire may wear unevenly, take measurement at several places. If any measurement is less than the service limit, replace the tire (see Tire Removal/Installation in the Wheels/Tires chapter).
•
Tread Depth Standard: Front: IRC
4.2 mm (0.17 in.)
BRIDGESTONE
4.6 mm (0.18 in.)
DUNLOP
4.5 mm (0.18 in.)
Rear: IRC
6.5 mm (0.26 in.)
BRIDGESTONE
7.0 mm (0.28 in.)
DUNLOP
7.4 mm (0.29 in.)
Service Limit: Front
1 mm (0.04 in.) (AT, CH, DE) 1.6 mm (0.06 in.)
Rear
2 mm (0.08 in.) (Up to 130 km/h (80 mph)) 3 mm (0.12 in.) (Over 130 km/h (80 mph))
WARNING To ensure safe handling and stability, use only the recommended standard tires for replacement, inflated to the standard pressure.
NOTE
○Most countries may have their own regulations a mini-
mum tire tread depth: be sure to follow them. ○Check and balance the wheel when a tire is replaced with a new one.
2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wheel Bearing Damage Inspection
the front wheel off the ground with the jack (see • Raise Front Wheel Removal in the Wheels/Tires chapter). the handlebar all the way to the right or left. • Turn Inspect roughness of the front wheel bearing by push• ing and the pulling [A] the wheel. [B] the front wheel lightly, and check for smoothly • Spin turn, roughness, binding or noise. If roughness, binding or noise is found, remove the front wheel and inspect the wheel bearing (see Front Wheel Removal, Hub Bearing Inspection in the Wheels/Tires chapter). the rear wheel off the ground with the stand (see • Raise Rear Wheel Removal in the Wheels/Tires chapter). the roughness of the rear wheel bearing by push• Inspect ing and pulling [A] the wheel. [B] the rear wheel lightly, and check for smoothly • Spin turn, roughness, binding or noise. If roughness, binding or noise is found, remove the rear wheel and inspect the wheel bearing (see Rear Wheel Removal, Hub Bearing Inspection in the Wheels/Tires chapter) and coupling (see Coupling Bearing Inspection in the Final Drive chapter).
Final Drive Drive Chain Lubrication Condition Inspection
a special lubricant is not available, a heavy oil such as • IfSAE 90 is preferred to a lighter oil because it will stay on
•
the chain longer and provide better lubrication. If the chain appears especially dirty, clean it before lubrication.
CAUTION The O-rings between the side plates seal in the lubricant between the pin and the bushing. To avoid damaging the O-rings and resultant loss of lubricant, observe the following rules. Use only kerosene or diesel oil for cleaning of the O -ring of the drive chain. Any other cleaning solution such as gasoline or trichloroethylene will cause deterioration and swelling of the O-ring. Immediately blow the chain dry with compressed air after cleaning. Complete cleaning and drying the chain within 10 minutes.
PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures oil to the sides of the rollers so that oil will penetrate • Apply to the rollers and bushings. Apply the oil to the O-rings so
•
that the O-rings will be coated with oil. Wipe off any excess oil. Oil Applied Areas [A] O-rings [B]
Drive Chain Slack Inspection NOTE
○Check the slack with the motorcycle setting on its sidestand.
○Clean the chain if it is dirty, and lubricate it if it appears dry.
the wheel alignment (see Wheel Alignment Inspec• Check tion). the rear wheel to find the position where the chain • Rotate is tightest. the vertical movement (chain slack) [A] midway • Measure between the sprockets. If the chain slack exceeds the standard, adjust it. Chain Slack Standard:
20 ∼ 30 mm (0.8 ∼ 1.2 in.)
Drive Chain Slack Adjustment
the cotter pin [A], and loosen the axle nut [B]. • Remove Loosen the chain adjuster locknuts [C]. • If the chain both is too loose, turn out the left and right chain
•
adjusters [D] evenly. If the chain is too tight, turn in the left and right chain adjusters evenly, and kick the wheel forward. Turn both chain adjusters evenly until the drive chain has the correct amount of slack. To keep the chain and wheel properly aligned, the notch [E] on the right wheel alignment indicator [F] should align with the same swingarm mark or position [G] that the left indicator notch aligns with.
WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition. both chain adjuster locknuts securely. • Tighten Tighten: •
Torque - Rear Axle Nut: 98 N·m (10.0 kgf·m, 72.3 ft·lb)
the wheel, measure the chain slack again at the tight• Turn est position, and readjust if necessary.
2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures
• Insert a new cotter pin [A].
NOTE
○When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [B] up to next alignment. ○It should be within 30°. ○Loosen once and tighten again when the slot goes past the nearest hole.
• Bend the cotter pin [A] over the nut. WARNING
If the rear axle nut is not securely tightened or the cotter pin is not installed, an unsafe riding condition may result.
Wheel Alignment Inspection
that the notch [A] on the left alignment indicator [B] • Check aligns with the same swingarm mark or position [C] that the right alignment indicator notch aligns with. If they do not, adjust the chain slack and align the wheel alignment (see Drive Chain Slack Adjustment).
○Wheel
NOTE
alignment can be also checked using the straightedge or string method.
WARNING Misalignment of the wheel will result in abnormal wear, and may result in an unsafe riding condition.
PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Drive Chain Wear Inspection
the chain cover (see Drive Chain Removal in the • Remove Final Drive chapter). the rear wheel to inspect the drive chain for dam• Rotate aged rollers, and loose pins and links.
• •
If there is any irregularity, replace the drive chain. Lubricate the drive chain if it appears dry. Stretch the chain taut by hanging a 98 N (10 kg, 20 lb) weight [A] on the chain. Measure the length of 20 links [B] on the straight part [C] of the chain from the pin center of the 1st pin to the pin center of the 21st pin. Since the chain may wear unevenly, take measurements at several places. If any measurements exceed the service limit, replace the chain. Also, replace the front and rear sprockets when the drive chain is replaced. Drive Chain 20-link Length Standard: 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.) Service Limit:
323 mm (12.7 in.)
WARNING If the drive chain wear exceeds the service limit, replace the chain or an unsafe riding condition may result. A chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the rear wheel, severely damaging the motorcycle and causing it to go out of control. For safely, use only the standard chain. It is an endless type and should not be cut for installation. Standard Chain Make: ENUMA Type:
EK520SR-O2
Link:
106 links
Chain Guide Wear Inspection
the swingarm (see Swingarm Removal in the • Remove Suspension chapter). inspect the chain guide [A]. • Visually Replace the chain guide if it shows any signs of abnormal wear or damage.
2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brakes Brake Fluid Leak (Brake Hose and Pipe) Inspection the brake lever or pedal and inspect the brake fluid • Apply leak from the brake hoses [A] and fittings [B].
If the brake fluid leaked from any position, inspect or replace the problem part.
Brake Hose and Pipe Damage and Installation Condition Inspection
the brake hoses and fittings for deterioration, • Inspect cracks and signs of leakage.
○The high pressure inside the brake line can cause fluid to
leak [A] or the hose to burst if the line is not properly maintained. Bend and twist the rubber hose while examining it. Replace the hose if any crack [B], bulge [C] or leakage is noticed. Tighten any brake hose banjo bolts. Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
the brake hose routing. • Inspect If any brake hose routing is incorrect, run the brake hose according to Cable, Wire, and Hose Routing section in the Appendix chapter.
Brake Fluid Level Inspection
that the brake fluid level in the front brake reservoir • Check [A] is above the lower level line [B].
NOTE
○Hold the reservoir horizontal by turning the handlebar when checking brake fluid level.
If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [C] in the reservoir.
PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures that the brake fluid level in the rear brake reservoir • Check [A] is above the lower level line [B]. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [C].
WARNING Change the brake fluid in the brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that is already in the reservoir are unidentified. After changing the fluid, use only the same type and brand of fluid thereafter. Recommended Disc Brake Fluid Grade: DOT4
procedure below to install the rear brake fluid • Follow reservoir cap correctly.
○First, tighten the rear brake fluid reservoir cap [B] clock-
wise [C] by hand until slight resistance is felt indicating that the cap is seated on the reservoir body, then tighten the cap an additional 1/6 turn [D] while holding the brake fluid reservoir body [A].
Brake Pad Wear Inspection
the brake pads (see Brake Pad Removal in the • Remove Brakes chapter). the lining thickness [A] of the pads in each caliper. • Check If the lining thickness of either pad is less than the service limit [B], replace both pads in the caliper as a set. Pad Lining Thickness Standard: Front
4.5 mm (0.18 in.)
Rear
4.5 mm (0.18 in.)
Service Limit:
1 mm (0.04 in.)
Brake Operation Inspection
the operation of the front and rear brake by run• Inspect ning the vehicle on the dry road. If the brake operation is insufficiency, inspect the brake system.
WARNING When inspecting by running the vehicle, note a surrounding traffic situation enough in the place of safety.
2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Light Switch Operation Inspection
on the ignition switch. • Turn The brake [A] should go on when the brake lever is • applied or light after the brake pedal is depressed about 10 mm (0.39 in.).
•
If it does not, adjust the brake light switch. While holding the switch body, turn the adjusting nut to adjust the switch. Switch Body [A] Adjusting Nut [B] Light sooner as the body rises [C] Light later as the body lowers [D]
CAUTION To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment. If it does not go on, inspect or replace the following items. Battery (see Charging Condition Inspection in the Electrical System chapter) Brake Light (see Tail/Brake Light Removal in the Electrical System chapter) Main Fuse 30 A and Taillight Fuse 10 A (see Fuse Inspection in the Electrical System chapter) Front Brake Light Switch [A] (see Switch Inspection in the Electrical System chapter) Rear Brake Light Switch (see Switch Inspection in the Electrical System chapter) Harness (see Wiring Inspection in the Electrical System chapter)
Suspension Front Forks/Rear Shock Absorber Operation Inspection
the forks down and up [A] 4 or 5 times, and inspect • Pump the smooth stroke. If the forks do not smoothly or noise is found, inspect the fork oil level or fork clamps (see Front Fork Oil Change in the Suspension chapter).
PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures the seat down and up [A] 4 or 5 times, and inspect • Pump the smooth stroke. If the shock absorber does not smoothly stroke or noise is found, inspect the oil leak (see Rear Shock Absorber Oil Leak Inspection).
Front Fork Oil Leak Inspection
inspect the front forks [A] for oil leakage. • Visually Replace or repair any defective parts, if necessary.
Rear Shock Absorber Oil Leak Inspection
inspect the shock absorber [A] for oil leakage. • Visually If the oil leakage is found on it, replace the shock absorber with a new one.
Rocker Arm Operation Inspection
the seat down and up 4 or 5 times, and inspect the • Pump smooth stroke. If the rocker arm [A] does not smoothly stroke or noise is found, inspect the fasteners and bearings (see Rocker Arm/Tie-Rod Bearing, Sleeve Inspection in the Suspension chapter).
Tie-Rod Operation Inspection
the seat down and up 4 or 5 times, and inspect the • Pump smooth stroke. If the tie-rods [A] do not smoothly stroke or noise is found, inspect the fasteners and tie-rod bearings (see Rocker Arm/Tie-Rod Bearing, Sleeve Inspection in the Suspension chapter).
2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Swingarm Pivot Lubrication
• Remove: Swingarm (see Swingarm Removal in the Suspension • • • •
chapter) Sleeve [A] Using a high-flash point solvent, clean the old grease out of the needle bearings [B]. Apply plenty of grease to the inner surface of the needle bearings. Apply thin coat of grease to the lips of the oil seals. Install the swingarm (see Swingarm Installation in the Suspension chapter).
Steering Steering Play Inspection
the lower fairings (see Lower Fairing Removal in • Remove the Frame chapter). • Raise the front wheel off the ground with the jack. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608
the front wheel pointing straight ahead, alternately • With tap each end of the handlebar. The front wheel should
•
swing fully left and right from the force of gravity until the fork hits the stop. If the wheel binds or catches before the stop, the steering is too tight. Feel for steering looseness by pushing and pulling the forks. If you feel looseness, the steering is too loose.
NOTE
○The cables and wiring will have some effect on the mo-
tion of the fork which must be taken into account. ○Be sure the leads and cables are properly routed. ○The bearings must be in good condition and properly lubricated in order for any test to be valid.
PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures Steering Play Adjustment
• Loosen: Lower Front Fork Clamp Bolts (Both Sides) •
Stem Head Bolt [A] Adjust the steering. Special Tool - Steering Stem Nut Wrench [B]: 57001-1100
If the steering is too tight, loosen the stem nut a fraction of a turn. If the steering is too loose, tighten the stem nut a fraction of a turn.
NOTE
○Turn the stem nut 1/8 turn at time maximum.
• Tighten:
Torque - Steering Stem Head Bolt: 44 N·m (4.5 kgf·m, 32 ft·lb) Lower Front Fork Clamp Bolts: 30 N·m (3.1 kgf·m, 22 ft·lb)
the steering again. • Check If the steering is still too tight or too loose, repeat the adjustment.
Steering Stem Bearing Lubrication
the steering stem (see Stem, Stem Bearing Re• Remove moval in the Steering chapter). a high-flash point solvent, wash the upper and • Using lower [A] ball bearings, and wipe the upper and lower
• • • •
outer races, which are press-fitted into the frame head pipe, clean off grease and dirt. Visually check the outer races and the ball bearings. Replace them if they show wear or damage. Apply a light coat of grease to the upper and lower ball bearings and outer races. Install the steering stem (see Stem, Stem Bearing Installation in the Steering chapter). Adjust the steering (see Steering Play Adjustment).
2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Electrical System Lights and Switches Operation Inspection First Step Turn on the ignition switch. The following lights should go on according to below table.
• •
Taillight [A]
goes on
License Plate Light [B]
goes on
Meter Panel Lights [C]
go on
Neutral Indicator Light [D]
goes on
Oil Pressure Warning Indicator Light [E]
goes on
FI Indicator Light [F] City Light [G]
goes on (about 2 seconds) goes on
If the light does not go on, inspect or replace the following item. Battery (see Charging Condition Inspection in the Electrical System chapter) Main Fuse 30 A and Taillight Fuse 10 A (see Fuse Inspection in the Electrical System chapter) Applicable Bulb (see Wiring Diagram in the Electrical System chapter) Taillight Bulb (see Tail/Brake Light Bulb Replacement in the Electrical System chapter) License Plate Light Bulb (see License Plate Light Bulb Replacement in the Electrical System chapter) Meter Unit for Meter Lights (see Meter, Indicator Light Replacement in the Electrical System chapter) Meter Unit for Neutral Indicator Light (see Meter, Indicator Light Replacement in the Electrical System chapter) Meter Unit for Oil Pressure Warning Indicator Light (see Meter, Indicator Light Replacement in the Electrical System chapter) FI Indicator Light (see Meter, Indicator Light Replacement in the Electrical System chapter) City Light Bulb (see City Light Bulb Replacement in the Electrical System chapter) Oil Pressure Switch (see Switch Inspection in the Electrical System chapter) ECU (see ECU Power Supply Inspection in the Fuel System (DFI) chapter) Ignition Switch (see Switch Inspection in the Electrical System chapter) Neutral Switch (see Switch Inspection in the Electrical System chapter) Harness (see Wiring Inspection in the Electrical System chapter) off the ignition switch. • Turn The all lights should go off. • If the light does not go off, replace the ignition switch.
PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures Second Step Turn on the turn signal switch [A] (left or right position). The left or right turn signal lights [B] (front and rear) according to the switch position should flash. The turn signal indicator light [C] in the meter unit should flash. If the each light does not flash, inspect or replace the following item. Turn Signal Light Bulb (see Turn Signal Light Bulb Replacement in the Electrical System chapter) Meter Unit for Turn Signal Indicator Light (see Meter, Indicator Light Replacement in the Electrical System chapter) Turn Signal Relay Fuse 10 A (see Fuse Inspection in the Electrical System chapter) Turn Signal Switch (see Switch Inspection in the Electrical System chapter) Turn Signal Relay (see Turn Signal Relay Inspection in the Electrical System chapter) Harness (see Wiring Inspection in the Electrical System chapter) Push the turn signal switch. The turn signal lights and indicator light should go off. If the light does not go off, inspect or replace the following item. Turn Signal Switch (see Switch Inspection in the Electrical System chapter) Turn Signal Relay (see Turn Signal Relay Inspection in the Electrical System chapter)
• • •
• •
Third Step Set the dimmer switch [A] to low beam position. Start the engine. The low beam headlight should go on. If the low beam headlight does not go on, inspect or replace the following item. Headlight Low Beam Bulb (see Headlight Bulb Replacement in the Electrical System chapter) Headlight Fuse 10 A (see Fuse Inspection in the Electrical System chapter) Dimmer Switch (see Switch Inspection in the Electrical System chapter) Headlight Relay in Relay Box (see Relay Circuit Inspection in the Electrical System chapter) Harness (see Wiring Inspection in the Electrical System chapter)
• • •
2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures the dimmer switch to high beam position. • Set The • go on.low beam [A] and high beam [B] headlights should high beam indicator light [C] should go on. • The If the high beam headlight and/or high beam indicator light
• •
• •
does not go on, inspect or replace the following item. Headlight High Beam Bulb (see Headlight Bulb Replacement in the Electrical System chapter) Dimmer Switch (see Switch Inspection in the Electrical System chapter) Turn off the engine stop switch. The low beam and high beam headlights should stay going on. If the headlights and high beam indicator light does go off, inspect or replace the following item. Headlight Relay in Relay Box (see Relay Circuit Inspection in the Electrical System chapter) Turn off the ignition switch. The headlights and high beam indicator light should go off.
Headlight Aiming Inspection
the headlight beam for aiming. • Inspect If the headlight beam points to one side rather than straight ahead, adjust the horizontal beam. Headlight Beam Horizontal Adjustment Turn the horizontal adjuster [A] on the headlight in or out until the beam points straight ahead. If the headlight beam points too low or high, adjust the vertical beam.
•
Headlight Beam Vertical Adjustment Turn the vertical adjuster [A] on the headlight in or out to adjust the headlight vertically.
•
NOTE
○ON high beam, the brightest points should be slightly below horizontal with the motorcycle on its wheels and the rider seated. Adjust the headlight to the proper angle according to local regulations.
PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures Sidestand Switch Operation Inspection
the sidestand switch [A] operation accordance to • Inspect the following table. Sidestand Switch Operation Sidestand
Gear Position
Clutch Lever
Engine Start
Engine Run
Up
Neutral
Released
Starts
Continue running
Up
Neutral
Pulled in
Starts
Continue running
Up
In Gear
Released
Doesn’t start
Stops
Up
In Gear
Pulled in
Starts
Continue running
Down
Neutral
Released
Starts
Continue running
Down
Neutral
Pulled in
Starts
Continue running
Down
In Gear
Released
Doesn’t start
Stops
Down
In Gear
Pulled in
Doesn’t start
Stops
If the sidestand switch operation does not work, inspect or replace the following item. Battery (see Charging Condition Inspection in the Electrical System chapter) Main Fuse 30 A (see Fuse Inspection in the Electrical System chapter) Ignition Fuse 10 A (see Fuse Inspection in the Electrical System chapter) Ignition Switch (see Switch Inspection in the Electrical System chapter) Sidestand Switch (see Switch Inspection in the Electrical System chapter) Engine Stop Switch (see Switch Inspection in the Electrical System chapter) Starter Button (see Switch Inspection in the Electrical System chapter) Neutral Switch (see Switch Inspection in the Electrical System chapter) Starter Relay (see Starter Relay Inspection in the Electrical System chapter) Relay Box (see Relay Circuit Inspection in the Electrical System chapter) Starter Circuit Relay (see Relay Circuit Inspection in the Electrical System chapter) Harness (see Wiring Inspection in the Electrical System chapter) If the all parts are good condition, replace the ECU (see ECU Removal/Installation in the Fuel System (DFI) chapter).
2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures Engine Stop Switch Operation Inspection First Step Turn on the ignition switch. Set the neutral position. Turn the engine stop switch to stop position [A]. Push the starter button. The engine does not start. If the engine starts, inspect or replace the following item. Engine Stop Switch (see Switch Inspection in the Electrical System chapter)
• • • • •
Second Step Turn on the ignition switch. Set the neutral position. Turn the engine stop switch to run position [A]. Push the starter button and run the engine. Turn the engine stop switch to stop position. Immediately the engine should be stop. If the engine does not stop, inspect or replace the following item. Engine Stop Switch (see Switch Inspection in the Electrical System chapter) If the engine stop switch is good condition, replace the ECU (see ECU Removal/Installation in the Fuel System (DFI) chapter).
• • • • • •
Others Chassis Parts Lubrication
lubricating each part, clean off any rusty spots with • Before rust remover and wipe off any grease, oil, dirt, or grime. • Lubricate the points listed below with indicated lubricant.
NOTE
○Whenever the vehicle has been operated under wet or rainy conditions, or especially after using a high-pressure water spray, perform the general lubrication. Pivots: Lubricate with Grease. Brake Lever Brake Pedal Clutch Lever Rear Brake Joint Pin Sidestand Points: Lubricate with Grease. Clutch Inner Cable Upper and Lower Ends [A] Throttle Inner Cable Upper and Lower Ends
PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures Cables: Lubricate with Rust Inhibitor. Clutch Cable Throttle Cables Lubricate the cables by seeping the oil between the cable and housing. ○The cable may be lubricated by using a commercially available pressure cable lubricator with an aerosol cable lubricant.
•
the cable disconnected at both ends, the cable • With should move freely [A] within the cable housing. If cable movement is not free after lubricating, if the cable is frayed [B], or if the cable housing is kinked [C], replace the cable.
2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures Bolts, Nuts and Fasteners Tightness Inspection
the tightness of the bolts and nuts listed here. Also, • Check check to see that each cotter pin is in place and in good condition.
NOTE
○For the engine fasteners, check the tightness of them when the engine is cold (at room temperature). If there are loose fasteners, retighten them to the specified torque following the specified tightening sequence. Refer to the appropriate chapter for torque specifications. If torque specifications are not in the appropriate chapter, see the Standard Torque Table. For each fastener, first loosen it by 1/2 turn, then tighten it. If cotter pins are damaged, replace them with new ones. Bolt, Nut and Fastener to be checked Engine: Clutch Lever Pivot Bolt Locknut Engine Mounting Bracket Bolts and Nuts Engine Mounting Nuts Exhaust Pipe Holder Nuts Exhaust Pipe Mounting Bolt Muffler Body Clamp Bolt Muffler Body Mounting Bolt Radiator Bolts Wheels: Front Axle Nut Rear Axle Nut Rear Axle Nut Cotter Pin Brakes: Brake Lever Pivot Bolt Locknut Brake Pedal Bolt Caliper Mounting Bolts Front Master Cylinder Clamp Bolts Rear Master Cylinder Mounting Bolts Rear Master Cylinder Push Rod Joint Cotter Pin Suspension: Front Fork Clamp Bolts Rear Shock Absorber Nuts Swingarm Pivot Shaft Nut Tie-Rod Nuts Uni-Trak Rocker Arm Nut Steering: Handlebar Mounting Bolts Steering Stem Head Bolt Others: Footpeg Bracket Bolts Sidestand Nut
PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures Replacement Parts Air Cleaner Element Replacement NOTE
○In dusty areas, the element should be replaced more frequently than the recommended interval.
○After riding through rain or on muddily roads, the element should be replaced immediately.
WARNING If dirt or dust is allowed to pass through into the throttle body assy, the throttle may become stuck, possibly causing accident.
CAUTION If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur.
• Remove: Right Side Cover (see Side Cover Removal in the Frame chapter) Air Cleaner Housing Cap Bolts [A] Air Cleaner Housing Cap [B]
• Pull out the air cleaner element [A].
• Separate the plastic holders [A].
a new element and air cleaner housing cap. • Install Tighten: •
Torque - Air Cleaner Housing Cap Bolts: 2.5 N·m (0.25 kgf·m, 22 in·lb)
2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel Hose Replacement
WARNING Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe because of residual pressure. Cover the hose connection with a piece of clean cloth to prevent fuel spillage. the fuel tank (see Fuel Tank Removal in the Fuel • Remove System (DFI) chapter). sure to place a piece of cloth [A] around the fuel hose • Be joint. • Push the joint lock claws [B].
the joint lock [A] as shown in the figure. • Pull Pull the fuel hose joint [B] out of the fuel supply pipe. •
the fuel hose with a new one. • Replace Pull [A] the joint lock [B] fully as shown in the figure. •
a new fuel hose so that the white mark side faces • Install fuel supply pipe of the fuel pump. the fuel hose joint [A] straight onto the fuel supply • Insert pipe until the hose joint clicks. • Push [B] the joint lock [C] until the hose joint clicks.
PERIODIC MAINTENANCE 2-45 Periodic Maintenance Procedures and pull [A] the fuel hose joint [B] back and forth • Push more than two times, and make sure it is locked and does not come off.
WARNING Make sure the fuel hose joint is installed correctly on the fuel supply pipe or the fuel could leak.
• • •
If it comes off, reinstall the hose joint. Run the fuel hose correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). Install the fuel tank (see Fuel Tank Installation in the Fuel System (DFI) chapter). Start the engine and check the fuel hose for leaks.
Coolant Change
WARNING To avoid burns, do not remove the radiator cap or try to change the coolant when the engine is still hot. Wait until it cools down. Coolant on tires will make them slippery and can cause an accident and injury. Immediately wipe up or wash away any coolant that spills on the frame, engine, or other painted parts. Since coolant is harmful to the human body, do not use for drinking. the lower fairings (see Lower Fairing Removal in • Remove the Frame chapter). the radiator cap [A] in two steps. First turn the • Remove cap counterclockwise to the first stop. Then push and turn it further in the same direction and remove the cap.
2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures a container under the coolant drain bolts [A], then • Place remove the drain bolts.
○The coolant will drain from the radiator and engine.
the hose [A]. • Remove Pour the into a suitable container. • Install thecoolant hose. • Tighten the drain bolts with the gasket. •○Replace the drain bolt gaskets with new ones. Torque - Coolant Drain Bolt (Water Pump): 9.8 N·m (1.0 kgf·m, 87 in·lb) Coolant Drain Bolt (Cylinder): 5.9 N·m (0.60 kgf·m, 52 in·lb)
filling the coolant, choose a suitable mixture ratio • When by referring to the coolant manufacturer’s directions.
CAUTION Soft or distilled water must be used with the antifreeze in the cooling system. If hard water is used in the system, it causes scales accumulation in the water passages, and considerably reduces the efficiency of the cooling system. Water and Coolant Mixture Ratio (Recommended) Soft Water: 50% Coolant:
50%
Freezing Point:
–35°C (–31°F)
Total Amount:
1.5 L (1.6 US qt)
PERIODIC MAINTENANCE 2-47 Periodic Maintenance Procedures
• Fill the radiator up to the filler neck [A] with coolant. NOTE
○Pour in the coolant slowly so that it can expel the air from the engine and radiator.
the cooling system for leaks. • Check Tap the • inside. radiator hoses to force any air bubbles caught • Fill the radiator up to the filler neck with coolant. the reserve tank up to the "F" (full) level line [A] with • Fill coolant and install the cap [B]. the radiator cap. • Install Start the warm it up thoroughly until the radiator • fan turns engine, on and then stop the engine. Check the coolant level in the reserve tank after the en• gine cools down. If the coolant level is lower than the "L" (low) level line [C], add coolant to the "F" level line.
CAUTION Do not add more coolant above the "F" level line.
2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures Radiator Hose and O-ring Replacement
the coolant (see Coolant Change). • Drain Remove: • Thermostat Housing [A] (see Thermostat Housing Re-
• •
moval in the Cooling System chapter) Water Pump Cover [B] (see Water Pump Cover Removal in the Cooling System chapter) O-rings [C] Hoses [D] Apply grease to the new O-rings and install them. Install the new hoses and tighten the clamps securely. Torque - Radiator (Water) Hose Clamp Screws: 1.5 N·m (0.15 kgf·m, 13 in·lb)
the coolant (see Coolant Change). • Fill • Check the cooling system for leaks.
Engine Oil Change
the motorcycle so that it is vertical after warming • Situate up the engine. the engine oil drain bolt [A] to drain the oil. •○Remove The oil in the oil filter can be drained by removing the filter
• •
(see Oil Filter Replacement). Replace the drain bolt gasket [B] with a new one. Tighten the drain bolt.
Torque - Engine Oil Drain Bolt (Oil Screen Cover): 19.6 N·m (2.0 kgf·m, 14.5 ft·lb)
• Pour in the specified type and amount of oil.
PERIODIC MAINTENANCE 2-49 Periodic Maintenance Procedures Recommended Engine Oil Type: API SE, SF or SG API SH, SJ or SL with JASO MA Viscosity:
SAE 10W-40
Capacity:
1.3 L (1.4 US qt) (when filter is not removed) 1.6 L (1.7 US qt) (when filter is removed) 1.7 L (1.8 US qt) (when engine is completely dry)
NOTE
○Although 10W-40 engine oil is the recommended oil for most conditions, the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area. the oil level (see Oil Level Inspection in the Engine • Check Lubrication System chapter).
Oil Filter Replacement
the engine oil (see Engine Oil Change). • Drain Remove the oil filter mounting bolt [A]. •
the oil filter with a new one. • Replace Apply engine oil to a new O-rings [A] before installation. • Install the oil filter, and tighten the mounting bolt [B]. •
Torque - Oil Filter Mounting Bolt: 19.6 N·m (2.0 kgf·m, 14.5 ft·lb)
in the specified type and amount of oil (see Engine • Pour Oil Change).
2-50 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose and Pipe Replacement CAUTION Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. the brake hose banjo bolts [A]. • Remove removing the brake hose, take care not to spill the • When brake fluid on the painted or plastic parts. removing the brake hoses [B], temporarily secure • When the end of the brake hose to some high place to keep fluid
• • •
loss to a minimum. Immediately wash away any brake fluid that spills. There are washers on each side of the brake hose fitting. Replace them with new ones when installing. Tighten: Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
installing the hoses, avoid sharp bending, kinking, • When flatting or twisting, and run the hoses according to Cable,
•
Wire, and Hose Routing section in the Appendix chapter. Fill the brake line after installing the brake hose (see Brake Fluid Change).
Brake Fluid Change NOTE
○The procedure to change the front brake fluid is as fol-
lows. Changing the rear brake fluid is the same as for the front brake.
the brake fluid reservoir. • Level Remove reservoir cap and diaphragm. • Remove the • caliper. the rubber cap [A] from the bleed valve on the a clear plastic hose [B] to the bleed valve, and run • Attach the other end of the hose into a container. • Fill the reservoir with fresh specified brake fluid.
PERIODIC MAINTENANCE 2-51 Periodic Maintenance Procedures the brake fluid. •○Change Repeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes. 1. Open the bleed valve [A]. 2. Apply the brake and hold it [B]. 3. Close the bleed valve [C]. 4. Release the brake [D].
NOTE
○The fluid level must be checked often during the chang-
ing operation and replenished with fresh brake fluid. If the fluid in the reservoir runs out any time during the changing operation, the brakes will need to be bled since air will have entered the brake line.
the clear plastic hose. • Remove Install the • Tighten: diaphragm and reservoir cap. •
Torque - Front Brake Reservoir Cap Screws: 1.5 N·m (0.15 kgf·m, 13 in·lb)
the procedure below to install the rear brake fluid • Follow reservoir cap correctly.
○First, tighten the rear brake fluid reservoir cap [B] clock-
wise [C] by hand until slight resistance is felt indicating that the cap is seated on the reservoir body, then tighten the cap an additional 1/6 turn [D] while holding the brake fluid reservoir body [A].
a non-permanent locking agent to the threads of • Apply the bleed valve. • Tighten the bleed valve, and install the rubber cap. Torque - Bleed Valve: 5.5 N·m (0.56 kgf·m, 49 in·lb)
changing the fluid, check the brake for good braking • After power, no brake drag, and no fluid leakage. If necessary, bleed the air from the lines.
Master Cylinder Rubber Parts Replacement Front Master Cylinder Disassembly Remove the front master cylinder (see Front Master Cylinder Removal in the Brakes chapter). Remove the reservoir cap and diaphragm, and pour the brake fluid into a container. Unscrew the locknut and pivot bolt, and remove the brake lever. Pull the dust cover out of place, and remove the circlip.
• • • •
Special Tool - Inside Circlip Pliers: 57001-143
out the piston [A], secondary cup [B], primary cup [C] • Pull and return spring [D].
CAUTION Do not remove the secondary cup from the piston since removal will damage it.
2-52 PERIODIC MAINTENANCE Periodic Maintenance Procedures Rear Master Cylinder Disassembly
NOTE
○Do not remove the push rod clevis for master cylinder
disassembly since removal requires brake position adjustment.
the rear master cylinder (see Rear Master Cylin• Remove der Removal in the Brakes chapter). • Remove the circlip [A]. Special Tool - Inside Circlip Pliers: 57001-143
out the push rod with the piston stop. • Pull off the piston [B], secondary cup [C], primary cup [D] • Take and return spring [E]. the circlip [F] and pull out the brake hose con• Remove nector [G] and O-ring [H]. Special Tool - Inside Circlip Pliers: 57001-143
CAUTION Do not remove the secondary cup from the piston since removal will damage it. Master Cylinder Assembly Before assembly, clean all parts including the master cylinder with brake fluid or alcohol.
•
CAUTION Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts. Do not use any other fluid for cleaning these parts. Gasoline, engine oil, or any other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any part will be difficult to wash off completely, and will eventually deteriorate the rubber used in the disc brake. brake fluid to the new parts and to the inner wall of • Apply the cylinder. care not to scratch the piston or the inner wall of the • Take cylinder. silicone grease to the brake lever pivot bolt and • Apply push rod. • Tighten:
Torque - Brake Lever Pivot Bolt: 5.9 N·m (0.60 kgf·m, 52 in·lb) Brake Lever Pivot Bolt Locknut: 5.9 N·m (0.60 kgf·m, 52 in·lb)
PERIODIC MAINTENANCE 2-53 Periodic Maintenance Procedures Caliper Rubber Parts Replacement
○The
NOTE
procedure to assembly/disassembly the front caliper is as follows. Assembling/disassembling the rear caliper is the same as for the front caliper.
Caliper Disassembly Remove: Front/Rear Caliper (see Front/Rear Caliper Removal in the Brakes chapter) Brake Pads (see Brake Pad Removal in the Brakes chapter) Pad Spring
•
compressed air, remove the pistons. •○Using Cover the piston area with a clean, thick cloth [A].
○Blow compressed air [B] into the hole for the banjo bolt to remove the piston.
WARNING To avoid serious injury, never place your fingers or palm in front of the piston. If you apply compressed air into the caliper, the piston may crush your hand or fingers. out the pistons by hand. • Pull Remove: • Caliper Holder Dust Seals Fluid Seals Bleed Valve Rubber Cap
NOTE
○If compressed air is not available, do as follows with the brake hose connected to the caliper.
○Prepare a container for brake fluid,
and perform the
work above it. the pads (see Brake Pad Removal in the Brakes chapter). ○Pump the brake lever until the pistons come out of the cylinders, and then disassemble the caliper.
○Remove
2-54 PERIODIC MAINTENANCE Periodic Maintenance Procedures Caliper Assembly Clean the caliper parts except for the pads.
•
CAUTION For cleaning the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol.
a non-permanent locking agent to the threads of • Apply the bleed valve. • Install the bleed valve and rubber cap. Torque - Bleed Valve: 5.5 N·m (0.56 kgf·m, 49 in·lb)
brake fluid to the cylinder bores. • Apply Replace the fluid seals [A] with new ones. •○Apply silicone grease to the fluid seals, and install them
•
into the cylinders by hand. Replace the dust seals [B] with new ones.
brake fluid to the outside of the pistons, and push • Apply them into each cylinder by hand. the dust cover [A] and the friction boot [B] replace • Check them with new ones if they are damaged. a thin coat of PBC (Poly Butyl Cuprysil) grease to • Apply the caliper holder shaft [C] and pin bolt [D] (PBC is a spe-
•
cial high-temperature, water-resistance grease). Install the caliper holder and pad spring.
the pads (see Brake Pad Installation in the Brakes • Install chapter). up any spilled brake fluid on the caliper with wet • Wipe cloth.
Spark Plug Replacement
the stick coils (see Stick Coil Removal in the • Remove Electrical System chapter). the spark plugs using the 16 mm (0.63 in.) plug • Remove wrench [A] vertically.
PERIODIC MAINTENANCE 2-55 Periodic Maintenance Procedures
• Replace the spark plug with a new one. Standard Spark Plug Type: NGK CR8E
the new spark plug in the plug hole, and finger • Insert -tighten it first. • Using the plug wrench [A] vertically, tighten the plug.
CAUTION
The insulator of the spark plug may break if when the wrench is inclined during tightening. Torque - Spark Plugs: 13 N·m (1.3 kgf·m, 115 in·lb)
the stick coils securely. •○Install Be sure the stick coils are installed by pulling up it lightly.
FUEL SYSTEM (DFI) 3-1
Fuel System (DFI) Table of Contents Exploded View........................................................................................................................ DFI System............................................................................................................................. DFI Parts Location.................................................................................................................. Specifications ......................................................................................................................... Special Tools and Sealant ...................................................................................................... DFI Servicing Precautions ...................................................................................................... DFI Servicing Precautions ................................................................................................... Troubleshooting the DFI System ............................................................................................ Outline ................................................................................................................................. Inquiries to Rider.................................................................................................................. DFI System Troubleshooting Guide ....................................................................................... Self-Diagnosis ........................................................................................................................ Self-diagnosis Outline ....................................................................................................... Self-diagnosis Procedures ................................................................................................ Service Code Clearing Procedures................................................................................... How to Read Service Codes............................................................................................. How to Erase Service Codes ............................................................................................ Service Code Table........................................................................................................... Backups ............................................................................................................................ Main Throttle Sensor (Service Code 11) ................................................................................ Main Throttle Sensor Removal/Adjustment ...................................................................... Main Throttle Sensor Input Voltage Inspection ................................................................. Main Throttle Sensor Output Voltage Inspection .............................................................. Main Throttle Sensor Resistance Inspection .................................................................... Inlet Air Pressure Sensor (Service Code 12).......................................................................... Inlet Air Pressure Sensor Removal................................................................................... Inlet Air Pressure Sensor Installation................................................................................ Inlet Air Pressure Sensor Input Voltage Inspection........................................................... Inlet Air Pressure Sensor Output Voltage Inspection........................................................ Inlet Air Temperature Sensor (Service Code 13).................................................................... Inlet Air Temperature Sensor Removal/Installation........................................................... Inlet Air Temperature Sensor Output Voltage Inspection .................................................. Inlet Air Temperature Sensor Resistance Inspection ........................................................ Water Temperature Sensor (Service Code 14) ...................................................................... Water Temperature Sensor Removal/Installation ............................................................. Water Temperature Sensor Output Voltage Inspection..................................................... Water Temperature Sensor Resistance Inspection........................................................... Crankshaft Sensor (Service Code 21).................................................................................... Crankshaft Sensor Removal/Installation........................................................................... Crankshaft Sensor Resistance Inspection ........................................................................ Crankshaft Sensor Peak Voltage Inspection..................................................................... Speed Sensor (Service Code 24, 25)..................................................................................... Speed Sensor Removal/Installation.................................................................................. Speed Sensor Inspection.................................................................................................. Speed Sensor Input Voltage Inspection............................................................................ Speed Sensor Output Voltage Inspection ......................................................................... Vehicle-down Sensor (Service Code 31)................................................................................ Vehicle-down Sensor Removal ......................................................................................... Vehicle-down Sensor Installation ...................................................................................... Vehicle-down Sensor Input Voltage Inspection.................................................................
3-4 3-8 3-14 3-17 3-19 3-21 3-21 3-23 3-23 3-26 3-29 3-34 3-34 3-34 3-35 3-37 3-37 3-38 3-39 3-41 3-41 3-41 3-42 3-43 3-44 3-44 3-44 3-44 3-45 3-50 3-50 3-50 3-51 3-53 3-53 3-53 3-54 3-55 3-55 3-55 3-55 3-56 3-56 3-56 3-56 3-57 3-59 3-59 3-59 3-59
3
3-2 FUEL SYSTEM (DFI) Vehicle-down Sensor Output Voltage Inspection .............................................................. Subthrottle Sensor (Service Code 32).................................................................................... Subthrottle Sensor Removal/Adjustment .......................................................................... Subthrottle Sensor Input Voltage Inspection..................................................................... Subthrottle Sensor Output Voltage Inspection .................................................................. Subthrottle Sensor Resistance Inspection ........................................................................ Oxygen Sensor - not activated (Service Code 33) ................................................................. Oxygen Sensor Removal/Installation................................................................................ Oxygen Sensor Inspection................................................................................................ Stick Coils #1, #2 (Service Code 51, 52)................................................................................ Stick Coil Removal/Installation.......................................................................................... Stick Coil Primary Winding Resistance Inspection ........................................................... Stick Coil Input Voltage Inspection.................................................................................... Radiator Fan Relay (Service Code 56)................................................................................... Radiator Fan Relay Removal/Installation.......................................................................... Radiator Fan Relay Inspection.......................................................................................... Subthrottle Valve Actuator (Service Code 62) ........................................................................ Subthrottle Valve Actuator Removal ................................................................................. Subthrottle Valve Actuator Inspection ............................................................................... Subthrottle Valve Actuator Resistance Inspection ............................................................ Subthrottle Valve Actuator Input Voltage Inspection ......................................................... Air Switching Valve (Service Code 64) ................................................................................... Air Switching Valve Removal/Installation .......................................................................... Air Switching Valve Inspection .......................................................................................... Oxygen Sensor Heater (Service Code 67) ............................................................................. Oxygen Sensor Heater Removal/Installation .................................................................... Oxygen Sensor Heater Resistance Inspection ................................................................. Oxygen Sensor Heater Power Source Voltage Inspection ............................................... Oxygen Sensor - Incorrect Output Voltage (Service Code 94)............................................... Oxygen Sensor Removal/Installation................................................................................ Oxygen Sensor Inspection................................................................................................ FI Indicator Light..................................................................................................................... Light Inspection................................................................................................................. ECU ........................................................................................................................................ ECU Identification ............................................................................................................. ECU Removal ................................................................................................................... ECU Installation ................................................................................................................ ECU Power Supply Inspection.......................................................................................... DFI Power Source .................................................................................................................. ECU Fuse Removal .......................................................................................................... ECU Fuse Installation ....................................................................................................... ECU Fuse Inspection ........................................................................................................ ECU Main Relay Removal/Installation .............................................................................. ECU Main Relay Inspection .............................................................................................. Fuel Line................................................................................................................................. Fuel Pressure Inspection .................................................................................................. Fuel Flow Rate Inspection ................................................................................................ Fuel Pump .............................................................................................................................. Fuel Pump Removal ......................................................................................................... Fuel Pump Installation ...................................................................................................... Fuel Pump Operation Inspection ...................................................................................... Fuel Pump Operating Voltage Inspection ......................................................................... Pressure Regulator Removal............................................................................................ Fuel Filter Cleaning........................................................................................................... Fuel Pump Relay Removal/Installation ............................................................................. Fuel Pump Relay Inspection ............................................................................................. Fuel Injectors ..........................................................................................................................
3-60 3-63 3-63 3-63 3-64 3-65 3-66 3-66 3-66 3-69 3-69 3-69 3-69 3-71 3-71 3-71 3-73 3-73 3-73 3-73 3-74 3-76 3-76 3-76 3-77 3-77 3-77 3-77 3-79 3-79 3-79 3-82 3-82 3-83 3-83 3-83 3-83 3-84 3-87 3-87 3-87 3-87 3-87 3-87 3-88 3-88 3-89 3-91 3-91 3-92 3-92 3-93 3-94 3-94 3-94 3-94 3-96
FUEL SYSTEM (DFI) 3-3 Fuel Injector Removal/Installation..................................................................................... Fuel Injector Audible Inspection........................................................................................ Fuel Injector Resistance Inspection .................................................................................. Fuel Injector Power Source Voltage Inspection ................................................................ Fuel Injector Output Voltage Inspection ............................................................................ Fuel Injector Fuel Line Inspection ..................................................................................... Throttle Grip and Cables ........................................................................................................ Free Play Inspection ......................................................................................................... Free Play Adjustment........................................................................................................ Cable Installation .............................................................................................................. Cable Lubrication .............................................................................................................. Throttle Body Assy ................................................................................................................. Idle Speed Inspection/Adjustment .................................................................................... Synchronization Inspection/Adjustment ............................................................................ Throttle Body Assy Removal............................................................................................. Throttle Body Assy Installation.......................................................................................... Throttle Body Assy Disassembly ...................................................................................... Throttle Body Assy Assembly ........................................................................................... Air Cleaner.............................................................................................................................. Air Cleaner Element Removal/Installation ........................................................................ Air Cleaner Element Inspection ........................................................................................ Air Cleaner Oil Draining .................................................................................................... Air Cleaner Housing Removal........................................................................................... Air Cleaner Housing Installation........................................................................................ Air Cleaner Housing Disassembly .................................................................................... Air Cleaner Housing Assembly ......................................................................................... Fuel Tank ................................................................................................................................ Fuel Tank Removal ........................................................................................................... Fuel Tank Installation ........................................................................................................ Fuel Tank Inspection ......................................................................................................... Fuel Tank Cleaning ...........................................................................................................
3-96 3-96 3-96 3-97 3-98 3-99 3-101 3-101 3-101 3-101 3-101 3-102 3-102 3-102 3-102 3-104 3-105 3-106 3-107 3-107 3-107 3-107 3-107 3-108 3-108 3-109 3-110 3-110 3-112 3-113 3-113
3-4 FUEL SYSTEM (DFI) Exploded View
FUEL SYSTEM (DFI) 3-5 Exploded View No. 1 2 3 4 5 6 7
Fastener Crankshaft Sensor Screws Delivery Pipe Assy Mounting Screws Inlet Air Temperature Sensor Screw Oxygen Sensor Speed Sensor Bolt Throttle Body Assy Holder Clamp Screws Water Temperature Sensor
8. Throttle Cable (Accelerator) 9. Throttle Cable (Decelerator) CL: Apply cable lubricant. EO: Apply engine oil. G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts SS: Apply silicone sealant.
N·m 3.0 3.4 1.2 44.1 7.8 2.0 25
Torque kgf·m 0.31 0.35 0.12 4.50 0.80 0.20 2.5
ft·lb 27 in·lb 30 in·lb 11 in·lb 32.5 69 in·lb 18 in·lb 18
Remarks
L
3-6 FUEL SYSTEM (DFI) Exploded View
FUEL SYSTEM (DFI) 3-7 Exploded View No. 1 2 3 4 5
Fastener Air Cleaner Housing Cap Bolts Air Cleaner Housing Mounting Bolts Air Cleaner Housing Screws Air Duct Clamp Screws Fuel Pump Bolts
AD: Apply adhesive. AO: Apply high-quality-form-air-filter oil. L: Apply a non-permanent locking agent. R: Replacement Parts
N·m 2.5 9.8 1.15 2.0 9.8
Torque kgf·m 0.25 1.0 0.12 0.20 1.0
ft·lb 22 in·lb 87 in·lb 10 in·lb 18 in·lb 87 in·lb
Remarks
L
3-8 FUEL SYSTEM (DFI) DFI System DFI System
FUEL SYSTEM (DFI) 3-9 DFI System 1. ECU 2. Battery 12 V 8 Ah 3. Neutral Switch 4. Inlet Air Pressure Sensor 5. Air Switching Valve 6. Water Temperature Sensor 7. Speed Sensor 8. Vehicle-down Sensor 9. Oxygen Sensor 10. Crankshaft Sensor 11. Main Throttle Sensor 12. Fuel Injectors 13. Subthrottle Valve Actuator 14. Subthrottle Sensor 15. Inlet Air Temperature Sensor 16. Fuel Pump
3-10 FUEL SYSTEM (DFI) DFI System DFI System Wiring Diagram
FUEL SYSTEM (DFI) 3-11 DFI System Part Names 1. Oxygen Sensor 2. ECU 3. Joint Connector 2 4. Kawasaki Diagnostic System Connector 5. Self-diagnosis Terminal 6. Fuel Pump 7. Battery 12 V 8 Ah 8. Frame Ground 9. Starter Relay 10. Main Fuse 30 A 11. Relay Box 12. Fuel Pump Relay 13. ECU Main Relay 14. Fan Relay 15. Ignition Fuse 10 A 16. ECU Fuse 15 A 17. Fan Fuse 10 A 18. Oxygen Sensor Heater Fuse 10 A 19. Fuse Box 20. Joint Connector 1 21. FI Indicator Light 22. Tachometer 23. Water Temperature Gauge 24. Ignition Switch 25. Engine Stop Switch 26. Starter Button 27. Fan Motor 28. Resistor 29. Stick Coil #1, #2 30. Water-proof Joint 3 31. Air Switching Valve 32. Speed Sensor 33. Subthrottle Valve Actuator 34. Subthrottle Sensor 35. Main Throttle Sensor 36. Inlet Air Pressure Sensor 37. Water-proof Joint 2 38. Vehicle-down Sensor 39. Fuel Injector #1, #2 40. Water-proof Joint 1 41. Water Temperature Sensor 42. Inlet Air Temperature Sensor 43. Crankshaft Sensor
○Color Codes: BK: Black BL: Blue BR: Brown CH: Chocolate DG: Dark Green G: Green
GY: Gray LB: Light Blue LG: Light Green O: Orange P: Pink
PU: Purple R: Red V: Violet W: White Y: Yellow
3-12 FUEL SYSTEM (DFI) DFI System Terminal Numbers of ECU Connectors
Terminal Names 1. Subthrottle Valve Actuator: W/BL 2. Subthrottle Valve Actuator: P 3. Fuel Level Warning Indicator Light: GY 4. Oxygen Sensor: BL/Y 5. Speed Sensor: LG/R 6. Main Throttle Sensor: Y/W 7. Inlet Air Pressure Sensor: Y/BL 8. Power Supply to Sensors: BL 9. Vehicle-down Sensor: Y/G 10. Neutral Switch: LG 11. Crankshaft Sensor (+): R/BK 12. Power Supply to ECU (from ECU Main Relay): BR/W 13. External Communication Line: LG/BK 14. Subthrottle Valve Actuator: G/Y 15. Subthrottle Valve Actuator: BK/BL 16. Unused 17. Water Temperature Sensor: O 18. Self-diagnosis Terminal: Y/BK 19. Subthrottle Sensor: BL/W 20. Inlet Air Temperature Sensor: Y 21. Unused 22. Ground for Sensors: BR/BK 23. Oxygen Sensor Heater: P/BK 24. Crankshaft Sensor (–): Y/BK 25. Unused 26. Ground for ECU: BK/Y 27. Power Supply to ECU (from Battery): W/BK 28. Engine Stop Switch: R 29. Starter Lockout Switch: R/G 30. Starter Button: BK/R 31. Fuel Pump Relay: BR/Y 32. Air Switching Valve: R/BL 33. Injector #2: BL/G 34. Injector #1: BL/R
FUEL SYSTEM (DFI) 3-13 DFI System 35. Stick Coil #1: BK 36. Sidestand Switch: G/BK 37. Fan Relay: P/W 38. Unused 39. Meter Unit (Tachometer): LB 40. FI Indicator Light: R/Y 41. Unused 42. Ground for Fuel System: BK/Y 43. Ground for Ignition System: BK/Y 44. Stick Coil #2: BK/G
3-14 FUEL SYSTEM (DFI) DFI Parts Location Main Throttle Sensor [A] Subthrottle Sensor [B]
Fuel Injectors #1, #2 [A]
Crankshaft Sensor [A]
Oxygen Sensor [A]
Ignition Switch [A] FI Indicator Light [B]
FUEL SYSTEM (DFI) 3-15 DFI Parts Location Stick Coils #1, #2 [A] Air Switching Valve [B] Inlet Air Pressure Sensor [C]
Subthrottle Valve Actuator [A]
Speed Sensor [A]
Water Temperature Sensor [A] Vehicle-down Sensor [B]
Inlet Air Temperature Sensor [A]
3-16 FUEL SYSTEM (DFI) DFI Parts Location Fuse Box (Oxygen Sensor Heater Fuse 10 A, ECU Fuse 15 A, Ignition Fuse 10 A, Fan Fuse 10 A ) [A] Battery 12 V 8 Ah [B] Relay Box (ECU Main Relay, Fan Relay, Fuel Pump Relay) [C] ECU [D] Kawasaki Diagnostic System Connector [E] Self-diagnosis Terminal [F]
Fuel Pump [A]
FUEL SYSTEM (DFI) 3-17 Specifications Item Digital Fuel Injection System Idle Speed Throttle Body Assy: Type Bore Throttle Body Vacuum Bypass Screws (Turn Out) ECU: Make Fuel Pressure (High Pressure Line) Fuel Pump: Discharge Fuel Injectors: Type Nozzle Type Resistance Main Throttle Sensor: Input Voltage Output Voltage
Resistance Inlet Air Pressure Sensor: Input Voltage Output Voltage Inlet Air Temperature Sensor: Output Voltage Resistance Water Temperature Sensor: Output Voltage Speed Sensor: Input Voltage Output Voltage Vehicle-down Sensor: Input Voltage Output Voltage
Standard 1 300 ±50 r/min (rpm) Two barrel type 28 mm (1.10 in.) 24.0 ±1.33 kPa (180 ±10 mmHg) 0 ∼ 2 1/2 (for reference) DENSO 294 kPa (3.0 kgf/cm², 43 psi) with engine idling 17 mL (0.57 US oz.) or more for 3 seconds INP-288 Fine atomizing type with 8 holes About 11.7 ∼ 12.3 Ω at 20°C (68°F) DC 4.75 ∼ 5.25 V DC 1.020 ∼ 1.050 V at idle throttle opening DC 4.185 ∼ 4.385 V at full throttle opening (for reference) 4 ∼ 6 kΩ DC 4.75 ∼ 5.25 V DC 3.80 ∼ 4.20 V at standard atmospheric pressure (see this text for details) About DC 2.25 ∼ 2.50 V at inlet air temperature 20°C (68°F) 5.4 ∼ 6.6 kΩ at 0°C (32°F) 0.29 ∼ 0.39 kΩ at 80°C (176°F) About DC 2.80 ∼ 2.97 V at 20°C (68°F) DC 4.75 ∼ 5.25 V About DC 0.05 ∼ 0.09 V or DC 4.5 ∼ 4.9 V at ignition switch ON and 0 km/h DC 4.75 ∼ 5.25 V With sensor tilted 55 ∼ 75° or more right or left: DC 3.7 ∼ 4.4 V With sensor arrow mark pointed up: DC 0.4 ∼ 1.4 V
3-18 FUEL SYSTEM (DFI) Specifications Item Subthrottle Sensor: Input Voltage Output Voltage
Resistance Subthrottle Valve Actuator: Resistance Input Voltage Oxygen Sensor: Output Voltage (Rich) Output Voltage (Lean) Heater Resistance Throttle Grip and Cables Throttle Grip Free Play Air Cleaner Element
Standard DC 4.75 ∼ 5.25 V DC 0.78 ∼ 0.82 V at subthrottle valve full close position DC 3.9 ∼ 4.1 V at subthrottle valve full open position (for reference) 4 ∼ 6 kΩ About 5.2 ∼ 7.8 Ω About DC 11.5 ∼ 13.5 V DC 0.7 V or more DC 0.2 V or less 11.7 ∼ 15.5 Ω at 20°C (68°F) 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Polyurethane foam
FUEL SYSTEM (DFI) 3-19 Special Tools and Sealant Oil Pressure Gauge, 5 kgf/cm²: 57001-125
Peak Voltage Adapter: 57001-1415
Fork Oil Level Gauge: 57001-1290
Needle Adapter Set: 57001-1457
Vacuum Gauge: 57001-1369
Throttle Sensor Setting Adapter: 57001-1538
Hand Tester: 57001-1394
Sensor Harness Adapter: 57001-1561
Throttle Sensor Setting Adapter #1: 57001-1400
Fuel Pressure Gauge Adapter: 57001-1593
3-20 FUEL SYSTEM (DFI) Special Tools and Sealant Fuel Hose: 57001-1607
Measuring Adapter: 57001-1700
Oxygen Sensor Measuring Adapter: 57001-1682
Kawasaki Bond (Silicone Sealant): 56019-120
FUEL SYSTEM (DFI) 3-21 DFI Servicing Precautions DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system.
○This DFI system is designed to be used with a 12 V sealed
battery as its power source. Do not use any other battery except for a 12 V sealed battery as a power source. ○Do not reverse the battery cable connections. This will damage the ECU. ○To prevent damage to the DFI parts, do not disconnect the battery cables or any other electrical connections when the ignition switch is ON, or while the engine is running. ○Take care not to short the leads that are directly connected to the battery positive (+) terminal to the chassis ground. ○When charging, remove the battery from the motorcycle. This is to prevent ECU damage by excessive voltage.
○Whenever the DFI electrical connections are to be dis-
connected, first turn off the ignition switch, and disconnect the battery (–) terminal. Do not pull the lead, only the connector. Conversely, make sure that all the DFI electrical connections are firmly reconnected before starting the engine. ○Connect these connectors until they click [A].
○Do not turn the ignition switch ON while any of the DFI
electrical connectors are disconnected. The ECU memorizes service codes. ○Do not spray water on the electrical parts, DFI parts, connectors, leads and wiring. ○If a transceiver is installed on the motorcycle, make sure that the operation of the DFI system is not influenced by electric wave radiated from the antenna. Check operation of the system with the engine at idle. Locate the antenna as far as possible away from the ECU. ○When any fuel hose is disconnected, do not turn on the ignition switch. Otherwise, the fuel pump will operate and fuel will spout from the fuel hose. ○Do not operate the fuel pump if the pump is completely dry. This is to prevent pump seizure. ○Before removing the fuel system parts, blow the outer surfaces of these parts clean with compressed air. ○When any fuel hose is disconnected, fuel may spout out by residual pressure in the fuel line. Cover the hose joint with a piece of clean cloth to prevent fuel spillage. ○When installing the fuel hoses, avoid sharp bending, kinking, flattening or twisting, and run the fuel hoses with a minimum of bending so that the fuel flow will not be obstructed. ○Run the hoses according to Cable, Wire, and Hose Routing section in the Appendix chapter. ○To prevent corrosion and deposits in the fuel system, do not add to fuel any fuel antifreeze chemicals.
3-22 FUEL SYSTEM (DFI) DFI Servicing Precautions
○If the motorcycle is not properly handled, the high pres-
sure inside the fuel line can cause fuel to leak or the hose to burst. Remove the fuel tank (see Fuel Tank Removal) and check the fuel hose [A]. Replace the fuel hose if any fraying, cracks or bulges are noticed.
○To maintain the correct fuel/air mixture (F/A), there must
be no inlet air leaks in the DFI system. Be sure to install the oil filler plug [A] after filling the engine oil. Torque - Oil Filler Plug: Hand-Tighten
FUEL SYSTEM (DFI) 3-23 Troubleshooting the DFI System Outline When an abnormality in the system occurs, the FI indicator light goes on to alert the rider on the meter panel. In addition, the condition of the problem is stored in the memory of the ECU (Electronic Control Unit). With the engine stopped and turned in the self-diagnosis mode, the service code [A] is indicated by the number of times the FI indicator light blinks. When due to a malfunction, the FI indicator light remains lit, ask the rider about the conditions [B] under which the problem occurred and try to determine the cause [C]. Don’t rely solely on the DFI self-diagnosis function, use common sense.
Even when the DFI system is operating normally, the FI indicator light [A] may light up under strong electrical interference. No remedy needed. Turn the ignition switch OFF to stop the indicator light. When the FI indicator light goes on and the motorcycle is brought in for repair, check the service codes. When the repair has been done, the light doesn’t go on. But the service codes stored in memory are not erased to preserve the problem history, and the light can display the codes in the self-diagnosis mode. The problem history is referred when solving unstable problems. When the motorcycle is down, the vehicle-down sensor operates and the ECU shuts off the fuel pump relay, fuel injectors and ignition system. The ignition switch is left ON. If the starter button is pushed, the electric starter turns but the engine does not start. When the starter button is pushed, the FI indicator light blinks but the service code is not displayed. To start the engine again, raise the motorcycle, turn the ignition switch OFF, and then ON. Much of the DFI system troubleshooting work consists of confirming continuity of the wiring. The DFI parts are assembled and adjusted with precision, and it is impossible to disassemble or repair them.
3-24 FUEL SYSTEM (DFI) Troubleshooting the DFI System checking the DFI parts, use a digital meter which • When can be read two decimal place voltage or resistance.
○The DFI part connectors [A] have seals [B], including the
ECU. When measuring the input or output voltage with the connector joined, use the needle adapter set [C]. Insert the needle adapter inside the seal until the needle adapter reaches the terminal. Special Tool - Needle Adapter Set: 57001-1457
CAUTION Insert the needle adapter straight along the terminal in the connector to prevent short-circuit between terminals. sure that measuring points are correct in the con• Make nector, noting the position of the lock [D] and the lead
• •
color before measurement. Do not reverse connections of a digital meter. Be careful not to short-circuit the leads of the DFI or electrical system parts by contact between adapters. Turn the ignition switch ON and measure the voltage with the connector joined.
CAUTION Incorrect, reverse connection or short circuit by needle adapters could damage the DFI or electrical system parts.
○After measurement, remove the needle adapters and ap-
ply silicone sealant to the seals [A] of the connector [B] for waterproofing. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120
check battery condition before replacing the DFI • Always parts. A fully charged battery is a must for conducting
• • •
accurate tests of the DFI system. Trouble may involve one or in some cases all items. Never replace a defective part without determining what CAUSED the problem. If the problem was caused by some other item or items, they too must be repaired or replaced, or the new replacement part will soon fail again. Measure coil winding resistance when the DFI part is cold (at room temperature). Make sure all connectors in the circuit are clean and tight, and examine leads for signs of burning, fraying, short, etc. Deteriorated leads and bad connections can cause reappearance of problems and unstable operation of the DFI system. If any wiring is deteriorated, replace the wiring.
FUEL SYSTEM (DFI) 3-25 Troubleshooting the DFI System each connector [A] apart and inspect it for corrosion, • Pull dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Connect the connectors securely. Check the wiring for continuity. ○Use the wiring diagram to find the ends of the lead which is suspected of being a problem. ○Connect the hand tester between the ends of the leads.
•
Special Tool - Hand Tester: 57001-1394
○Set the tester to the × 1 Ω range, and read the tester.
If the tester does not read 0 Ω, the lead is defective. Replace the lead or the main harness or the subharness.
○If both ends of a harness [A] are far apart, ground [B] the one end [C], using a jumper lead [D] and check the continuity between the end [E] and the ground [F]. This enables to check a long harness for continuity. If the harness is open, repair or replace the harness.
○When checking a harness [A] for short circuit, open one end [B] and check the continuity between the other end [C] and ground [D]. If there is continuity, the harness has a short circuit to ground, and it must be repaired or replaced.
down suspicious locations by repeating the con• Narrow tinuity tests from the ECU connectors. If no abnormality is found in the wiring or connectors, the DFI parts are the next likely suspects. Check the part, starting with input and output voltages. However, there is no way to check the ECU itself. If an abnormality is found, replace the affected DFI part. If no abnormality is found in the wiring, connectors, and DFI parts, replace the ECU.
3-26 FUEL SYSTEM (DFI) Troubleshooting the DFI System DFI Diagnosis Flow Chart
Inquiries to Rider
○Each rider reacts to problems in different ways, so it is important to confirm what kind of symptoms the rider has encountered.
○Try to find out exactly what problem occurred under exactly what conditions by asking the rider; knowing this information may help you reproduce the problem. ○The following sample diagnosis sheet will help prevent you from overlooking any areas, and will help you decide if it is a DFI system problem, or a general engine problem.
FUEL SYSTEM (DFI) 3-27 Troubleshooting the DFI System Sample Diagnosis Sheet Rider name: Registration No. (license plate No.): Year of initial registration: Model: Engine No.: Frame No.: Date problem occurred: Mileage: Environment when problem occurred. Weather □ fine, □ cloudy, □ rain, □ snow, □ always, □ other: Temperature □ hot, □ warm, □ cold, □ very cold, □ always, □ other: Problem □ chronic, □ often, □once frequency Road □ street, □ highway, □ mountain road (□ uphill, □ downhill), □ bumpy, □ pebble Altitude □ normal, □ high (about 1 000 m or more) Motorcycle conditions when problem occurred. FI indicator □ lights up immediately after ignition switch ON, and goes off after 1 ∼ 2 seconds light (normal). □ lights up immediately after ignition switch ON, and stays on (DFI problem). □ unlights (light, ECU or its wiring fault). □ sometimes lights up (probably wiring fault). □ starter motor not rotating. Starting difficulty □ starter motor rotating but engine do not turn over. □ starter motor and engine do not turn over. □ no fuel flow (□ no fuel in tank, □ no fuel pump sound). □ no spark. □ other: Engine stalls □ right after starting. □ when opening throttle grip. □ when closing throttle grip. □ when moving off. □ when stopping the motorcycle. □ when cruising. □ other: Poor running □ very low idle speed, □ very high idle speed, □ rough idle speed. at low speed □ battery voltage is low (charge the battery). □ spark plug loose (tighten it). □ spark plug dirty, broken, or gap maladjusted (remedy it). □ backfiring. □ afterfiring. □ hesitation when acceleration. □ engine oil viscosity too high. □ brake dragging. □ engine overheating. □ clutch slipping. □ other:
3-28 FUEL SYSTEM (DFI) Troubleshooting the DFI System Poor running or no power at high speed
□ spark plug loose (tighten it). □ spark plug dirty, broken, or gap maladjusted (remedy it). □ spark plug incorrect (replace it). □ knocking (fuel poor quality or incorrect). □ brake dragging. □ clutch slipping. □ engine overheating. □ engine oil level too high. □ engine oil viscosity too high. □ other:
FUEL SYSTEM (DFI) 3-29 DFI System Troubleshooting Guide NOTE
○This is not an exhaustive list, giving every possible cause for each problem listed.
It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties in DFI system. ○The ECU may be involved in the DFI electrical and ignition system troubles. If these parts and circuits are checked out good, be sure to check the ECU for ground and power supply. If the ground and power supply are checked good, replace the ECU.
Engine Won’t Turn Over Symptoms or Possible Causes Neutral, starter lockout or sidestand switch trouble Vehicle-down sensor operated Vehicle-down sensor trouble Crankshaft sensor trouble Stick coil shorted or not in good contact Stick coil trouble Spark plug dirty, broken or gap maladjusted Spark plug incorrect ECU ground and power supply trouble ECU trouble No or little fuel in tank Fuel injector trouble Fuel pump not operating Fuel pump relay trouble Fuel filter or pump screen clogged Fuel pressure regulator trouble Fuel line clogged
Actions Inspect each switch (see chapter 16). Turn ignition switch OFF (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 16). Inspect or Reinstall (see chapter 16). Inspect (see chapter 16). Inspect and replace (see chapter 2). Replace it with the correct plug (see chapter 2). Inspect (see chapter 3). Inspect (see chapter 3). Supply fuel (see Owner’s Manual). Inspect and replace (see chapter 3). Inspect (see chapter 3). Inspect and replace (see chapter 3). Inspect and replace fuel pump (see chapter 3). Inspect fuel pressure and replace fuel pump (see chapter 3). Inspect and repair (see chapter 3).
Poor Running at Low Speed Symptoms or Possible Causes Spark weak: Stick coil shorted or not in good contact Stick coil trouble Spark plug dirty, broken or gap maladjusted Spark plug incorrect ECU trouble Fuel/air mixture incorrect: Little fuel in tank Air cleaner clogged, poorly sealed, or missing Air duct loose Throttle body assy holder loose Throttle body assy dust seal damage Fuel injector O-ring damage Fuel filter or pump screen clogged
Actions Inspect or Reinstall (see chapter 16). Inspect (see chapter 16). Inspect and replace (see chapter 2). Replace it with the correct plug (see chapter 2). Inspect (see chapter 3). Supply fuel (see Owner’s Manual). Clean element or inspect sealing (see chapter 2). Reinstall (see chapter 3). Reinstall (see chapter 3). Replace (see chapter 3). Replace (see chapter 3). Inspect and replace fuel pump (see chapter 3).
3-30 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Symptoms or Possible Causes Fuel pressure regulator trouble Fuel line clogged Inlet air pressure sensor trouble Water temperature sensor trouble Inlet air temperature sensor trouble Main throttle sensor trouble Subthrottle sensor trouble Subthrottle valve actuator trouble Unstable (rough) idling: Fuel pressure too low or too high Fuel injector trouble Main throttle sensor trouble Subthrottle sensor trouble Subthrottle valve actuator trouble Engine vacuum not synchronizing Inlet air pressure sensor trouble Water temperature sensor trouble Inlet air temperature sensor trouble Engine stalls easily: Spark plug dirty, broken or gap maladjusted Stick coil trouble Main throttle sensor trouble Subthrottle sensor trouble Subthrottle valve actuator trouble Inlet air pressure sensor trouble Water temperature sensor trouble Inlet air temperature sensor trouble Fuel pump trouble Fuel injector trouble Fuel pressure too low or too high Fuel pressure regulator trouble Fuel line clogged Poor acceleration: Fuel pressure too low Water or foreign matter in fuel Fuel filter or pump screen clogged Fuel pump trouble Fuel injector trouble Main throttle sensor trouble Subthrottle sensor trouble Subthrottle valve actuator trouble Inlet air pressure sensor trouble
Actions Inspect fuel pressure and replace fuel pump (see chapter 3). Inspect and repair (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 3). Inspect Inspect Inspect Inspect Inspect Inspect Inspect Inspect Inspect
(see chapter 3). (see chapter 3). (see chapter 3). (see chapter 3). (see chapter 3). and adjust (see chapter 2). (see chapter 3). (see chapter 3). (see chapter 3).
Inspect and replace (see chapter 2). Inspect (see chapter 16). Inspect (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 3). Inspect fuel pressure and replace fuel pump (see chapter 3). Inspect and repair (see chapter 3). Inspect (see chapter 3). Change fuel. Inspect and clean fuel system (see chapter 3). Inspect and replace fuel pump (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 3).
FUEL SYSTEM (DFI) 3-31 DFI System Troubleshooting Guide Symptoms or Possible Causes Water temperature sensor trouble Inlet air temperature sensor trouble Spark plug dirty, broken or gap maladjusted Stick coil trouble Stumble: Fuel pressure too low Fuel injector trouble Main throttle sensor trouble Subthrottle sensor trouble Subthrottle valve actuator trouble Inlet air pressure sensor trouble Water temperature sensor trouble Inlet air temperature sensor trouble Surge: Unstable fuel pressure
Fuel injector trouble Water temperature sensor trouble Backfiring when deceleration: Spark plug dirty, broken or gap maladjusted Fuel pressure too low Fuel pump trouble Main throttle sensor trouble Subthrottle sensor trouble Subthrottle valve actuator trouble Inlet air pressure sensor trouble Water temperature sensor trouble Inlet air temperature sensor trouble Air switching valve trouble Air suction valve trouble After fire: Spark plug burned or gap maladjusted Fuel injector trouble Inlet air pressure sensor trouble Water temperature sensor trouble Inlet air temperature sensor trouble Other: Intermittent any DFI fault and its recovery
Actions Inspect (see chapter 3). Inspect (see chapter 3). Inspect and replace (see chapter 2). Inspect (see chapter 16). Inspect Inspect Inspect Inspect Inspect Inspect Inspect Inspect
(see (see (see (see (see (see (see (see
chapter chapter chapter chapter chapter chapter chapter chapter
3). 3). 3). 3). 3). 3). 3). 3).
Fuel pressure regulator trouble (Inspect and replace fuel pump) or kinked fuel line (Inspect and replace fuel pump) (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 3). Inspect and replace (see chapter 2). Inspect (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 3). Inspect and replace (see chapter 16). Inspect and replace (see chapter 5). Replace (see chapter 2). Inspect (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 3). Check that DFI connectors are clean and tight, and examine leads for signs of burning or fraying (see chapter 3).
3-32 FUEL SYSTEM (DFI) DFI System Troubleshooting Guide Poor Running or No Power at High Speed Symptoms or Possible Causes Firing incorrect: Stick coil shorted or not in good contact Stick coil trouble Spark plug dirty, broken or gap maladjusted Spark plug incorrect ECU trouble Fuel/air mixture incorrect: Air cleaner clogged, poorly sealed, or missing Air duct loose Throttle body assy holder loose Throttle body assy dust seal damage Water or foreign matter in fuel
Actions Inspect or Reinstall (see chapter 16). Inspect (see chapter 16). Inspect and replace (see chapter 2). Replace it with the correct plug (see chapter 2). Inspect (see chapter 3).
Clean element or inspect sealing (see chapter 2). Reinstall (see chapter 3). Reinstall (see chapter 3). Replace (see chapter 3). Change fuel. Inspect and clean fuel system (see chapter 3). Fuel injector O-ring damage Replace (see chapter 3). Fuel injector clogged Inspect and repair (see chapter 3). Fuel line clogged Inspect and repair (see chapter 3). Fuel pump operates intermittently and often DFI Fuel pump bearings may wear. Replace the fuel fuse blows. pump (see chapter 3). Fuel pump trouble Inspect (see chapter 3). Inlet air pressure sensor trouble Inspect (see chapter 3). Cracked or obstructed inlet air pressure sensor Inspect and repair or replace (see chapter 3). vacuum hose Water temperature sensor trouble Inspect (see chapter 3). Inlet air temperature sensor trouble Inspect (see chapter 3). Main throttle sensor trouble Inspect (see chapter 3). Subthrottle sensor trouble Inspect (see chapter 3). Subthrottle valve actuator trouble Inspect (see chapter 3). Knocking: Fuel poor quality or incorrect Fuel change (Use the gasoline recommended in the Owner’s Manual). Spark plug incorrect Replace it with the correct plug (see chapter 2). Stick coil trouble Inspect (see chapter 16). ECU trouble Inspect (see chapter 3). Engine vacuum not synchronizing Inspect and adjust (see chapter 2). Inlet air pressure sensor trouble Inspect (see chapter 3). Water temperature sensor trouble Inspect (see chapter 3). Inlet air temperature sensor trouble Inspect (see chapter 3). Miscellaneous: Subthrottle sensor trouble Inspect (see chapter 3). Subthrottle valve actuator trouble Inspect (see chapter 3). Speed sensor trouble Inspect (see chapter 3). Throttle valves will not fully open Inspect throttle cables and lever linkage (see chapter 3).
FUEL SYSTEM (DFI) 3-33 DFI System Troubleshooting Guide Symptoms or Possible Causes Engine overheating - Water temperature sensor, crankshaft sensor or speed sensor trouble Air switching valve trouble Air suction valve trouble Exhaust Smokes Excessively: (Black smoke) Air cleaner element clogged Fuel pressure too high Fuel injector trouble Water temperature sensor trouble Inlet air temperature sensor trouble (Brown smoke) Air duct loose Fuel pressure too low Water temperature sensor trouble Inlet air temperature sensor trouble
Actions (see Overheating of Troubleshooting Guide in chapter 17) Inspect and replace (see chapter 16). Inspect and replace (see chapter 5).
Clean element (see chapter 2). Inspect (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 3). Reinstall (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 3). Inspect (see chapter 3).
3-34 FUEL SYSTEM (DFI) Self-Diagnosis Self-diagnosis Outline The self-diagnosis system has three modes and can be switched to another mode by grounding the self-diagnosis terminal. User Mode The ECU notifies the rider of troubles in DFI system and ignition system by lighting the FI indicator light when DFI system and ignition system parts are faulty, and initiates fail-safe function. In case of serious troubles, the ECU stops the injection/ignition/starter motor operation. Dealer Mode 1 The FI indicator light emits service code(s) to show the problem(s) which the DFI system, and ignition system has at the moment of diagnosis. Dealer Mode 2 The FI indicator light emits service code(s) to show the problem(s) which the DFI system, and ignition system had in the past.
Self-diagnosis Procedures
○When a problem occurs with the DFI system and ignition system, the FI indicator light [A] goes on.
○Use
NOTE
a fully charged battery when conducting self-diagnosis. Otherwise, the FI indicator light blinks very slowly or doesn’t blink. ○Keep the self-diagnosis terminal grounded during self -diagnosis, with an auxiliary lead. the front seat (see Front Seat Removal in the • Remove Frame chapter). the self-diagnosis terminal [A] (Yellow lead) to the • Ground battery (–) terminal, using a wire.
on the ignition switch. • Turn Connect an auxiliary lead [A] to the self-diagnosis terminal • [B] for grounding. enter the self-diagnosis dealer mode 1, ground [C] the • To self-diagnosis indicator terminal to the battery (–) terminal for more than 2 seconds [D], and then keep it grounded continuously [E]. ○Count the blinks of the FI indicator light to read the service code. Keep the auxiliary lead ground until you finish reading the service code.
FUEL SYSTEM (DFI) 3-35 Self-Diagnosis enter the self-diagnosis dealer mode 2, open [A] and • To ground [B] the lead more than five times [C] within 2 seconds [D] after the lead is first grounded, and then keep it grounded continuously [E] for more than 2 seconds. ○Count the blinks of the FI indicator light to read the service code. Keep the auxiliary lead ground until you finish reading the service code. Auxiliary Lead [F] Self-diagnosis Terminal [G]
NOTE
○To enter the dealer mode 2 from the dealer mode 1, turn off the ignition switch once.
Service Code Clearing Procedures the self-diagnosis • Enter -diagnosis Procedures).
○Make
dealer mode 2 (see Self
NOTE
sure to keep the grounding until the following opening and grounding starts.
the clutch lever in more than 5 seconds, and then • Pull release it. opening [A] and grounding [B] the lead • Repeat (self-diagnosis terminal) more than five times [C] within 2 seconds [D] after the lead is grounded, and then keep it grounded continuously [E] for more than 2 seconds. Auxiliary Lead [F] Self-diagnosis Terminal [G]
3-36 FUEL SYSTEM (DFI) Self-Diagnosis
FUEL SYSTEM (DFI) 3-37 Self-Diagnosis How to Read Service Codes
○Service codes are shown by a series of long and short blinks of the FI indicator light as shown below. ○Read 10th digit and unit digit as the FI indicator light blinks. ○When there are a number of problems, all the service codes can be stored and the display will
begin starting from the lowest number service code in the numerical order. Then after completing all codes, the display is repeated until the self-diagnosis indicator terminal is open. ○If there is no problem, no code and unlight. ○For example, if two problems occurred in the order of 21, 12, the service codes are displayed from the lowest number in the order listed. (12 → 21) → (12 → 21) → · · · (repeated)
○If the problem is with the following parts, the ECU cannot memorize these problems, the FI indicator light doesn’t go on, and no service codes can be displayed. FI Indicator Light Fuel Pump Fuel Pump Relay ECU Main Relay ECU Power Source Wiring and Ground Wiring (see ECU Power Supply Inspection) Fuel Injectors
How to Erase Service Codes
○Even if the ignition switch is turned OFF, the battery or the ECU are disconnected or the problem is solved, all service codes remain in the ECU.
○Refer to the Service Code Clearing Procedure for the service code erasure.
3-38 FUEL SYSTEM (DFI) Self-Diagnosis Service Code Table Service Code
FI Indicator Light
Main throttle sensor malfunction, wiring open or short Inlet air pressure sensor malfunction, wiring open or short Inlet air temperature sensor malfunction, wiring open or short Water temperature sensor malfunction, wiring open or short Crankshaft sensor malfunction, wiring open or short
11 12 13 14 21 24 and 25 31 32 33 51 52
Problems
+
Speed sensor malfunction, wiring open or short First 24 is displayed and then 25, repeatedly Vehicle-down sensor, malfunction, wiring open or short Subthrottle sensor malfunction, wiring open or short Oxygen sensor inactivation, wiring open or short Stick coil #1 malfunction, wiring open or short Stick coil #2 malfunction, wiring open or short
56
Radiator fan relay malfunction, wiring open or short
62
Subthrottle valve actuator malfunction, wiring open or short
64
Air switching valve malfunction, wiring open or short
67
Oxygen sensor heater malfunction, wiring open or short
94
Oxygen sensor malfunction, wiring open or short
Notes: ○The ECU may be involved in these problems. If all the parts and circuits checked out good, be sure to check the ECU for ground and power supply. If the ground and power supply are checked good, replace the ECU. ○When no service code is displayed, the electrical parts of the DFI system has no fault, and the mechanical parts of the DFI system and the engine are suspect.
FUEL SYSTEM (DFI) 3-39 Self-Diagnosis Backups
○The ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles.
Service Codes
Parts
11
Main Throttle Sensor
12
Inlet Air Pressure Sensor
13
14
21
24 and 25
Inlet Air Temperature Sensor Water Temperature Sensor
Output Signal Usable Range or Criteria
Output Voltage 0.2 ∼ 4.8 V
Inlet Air Pressure (Absolute) Pv = 150 ∼ 800 mmHg Inlet Air Temperature Ta = –30 ∼ +120°C Water Temperature Tw = –30 ∼ +120°C
Crankshaft sensor must send 22 signals to the ECU at the one cranking. Speed sensor must send 4 signals to the ECU at the one rotation Speed Sensor of the engine sprocket. The gear position is decided by the signal of the speed sensor. Crankshaft Sensor
31
Vehicle-down Sensor
Output Voltage 0.4 ∼ 4.4 V
32
Subthrottle Sensor
Output Voltage 0.15 ∼ 4.85 V
33
51
The oxygen sensor is active and sensor must Oxygen Sensor send signals (output voltage) continuously to the ECU. The stick coil primary winding must send Stick Coil #1* signals continuously to the ECU.
Backups by ECU If the main throttle sensor system fails (the output voltage is out of the usable range, wiring short or open), the ECU locks ignition timing into the ignition timing at closed throttle position and sets the DFI in the D-J method. Also, the main throttle sensor system and inlet air pressure fails, the ECU locks ignition timing into the ignition timing at closed throttle position and sets the DFI in the α-N method. If the inlet air pressure sensor system fails (the signal is out of the usable range, wiring short or open), the ECU sets the DFI in the α-N method. If the inlet air temperature sensor fails (the signal is out of the usable range, wiring short or open), the ECU sets Ta at 40°C. If the water temperature sensor system fails (the signal is out of the usable range, wiring short or open), the ECU sets Tw at 80°C. If the crankshaft sensor generates other than 22 signals, the engine stops by itself.
If the speed sensor system fails (no signal, wiring short or open), the speedometer shows 0, and the ECU sets the top (6) gear position.
If the vehicle-down sensor system has failures (the output voltage is more than usable range, wiring open), the ECU shuts off the fuel pump relay, the fuel injectors and the ignition system. If the subthrottle sensor system fails (the output voltage is out of the usable range, wiring short or open), the ECU drive the subthrottle valve to the full closed position, and it stops the current to the subthrottle valve actuator. If the oxygen sensor is not activated, the ECU stops the feedback mode of the oxygen sensor. If the stick coil #1 primary winding has failures (no signal, wiring short or open), the ECU shuts off the injector #1 to stop fuel to the cylinder #1, though the engine keeps running.
3-40 FUEL SYSTEM (DFI) Self-Diagnosis Service Codes 52
56
62
64
67
94
Output Signal Usable Range or Criteria The stick coil primary winding must send Stick Coil #2* signals continuously to the ECU. When the relay OFF Radiator Fan condition, the fan relay Relay is open. The actuator operates open and close of the Subthrottle subthrottle valve by the Valve Actuator pulse signal from the ECU. The air switching valve controls the flow of Air Switching the secondary air by Valve opening and shutting the solenoid valve. The oxygen sensor heater raise Oxygen Sensor temperature of the sensor for its earlier Heater activation. 12 V - 6.6 W, 0.55 A The oxygen sensor must send signals Oxygen Sensor continuously to the ECU Parts
Backups by ECU If the stick coil #2 primary winding has failures (no signal, wiring short or open), the ECU shuts off the injector #2 to stop fuel to the cylinder #2, though the engine keeps running. – If the subthrottle valve actuator fails (the signal is out of the usable range, wiring short or open), the ECU stops the current to the actuator.
–
If the oxygen sensor heater fails (wiring short or open), the ECU stops the current to the heater.
If the oxygen sensor output voltage is incorrect, the ECU stops the feedback mode of the oxygen sensor.
Note: (1) α-N Method: the DFI control method from medium to heavy engine load. When the engine load is light like at idling or low speed, the ECU determines the injection quantity by calculating from the throttle vacuum (inlet air pressure sensor output voltage) and engine speed (crankshaft sensor output voltage). This method is called D-J method. As the engine speed increases, and the engine load turns middle to heavy, the ECU determines the injection quantity by calculating from the throttle opening (main throttle sensor output voltage) and the engine speed. This method is called α-N method. *: This depends on the number of stopped cylinders.
FUEL SYSTEM (DFI) 3-41 Main Throttle Sensor (Service Code 11) Main Throttle Sensor Removal/Adjustment CAUTION Do not remove or adjust the main throttle sensor [A] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy especially on a hard surface. Such a shock to the main throttle sensor can damage it.
Main Throttle Sensor Input Voltage Inspection NOTE
○Be sure the battery is fully charged.
the ignition switch OFF. • Turn Remove the right lower fairing (see Lower Fairing Re• moval in the Frame chapter). Disconnect the throttle sensor connector and con• nect the harnessmain adapter [A] between these connectors. Special Tool - Throttle Sensor Setting Adapter: -1538
57001
• Connect a digital meter to the harness adapter leads. Main Throttle Sensor Input Voltage Connections to Adapter: Digital Meter (+) → BK (sensor BL) lead Digital Meter (–) → W (sensor BR/BK) lead
the input voltage with the engine stopped and • Measure with the connector joined. • Turn the ignition switch ON. Input Voltage Standard: DC 4.75 ∼ 5.25 V
the ignition switch OFF. • Turn If the reading is within the standard, check the output voltage (see Main Throttle Sensor Output Voltage Inspection). If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→ Main Throttle Sensor Connector [B] BL lead (ECU terminal 8) [C] BR/BK lead (ECU terminal 22) [D]
If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).
3-42 FUEL SYSTEM (DFI) Main Throttle Sensor (Service Code 11) Main Throttle Sensor Output Voltage Inspection
the output voltage at the main throttle sensor in • Measure the same way as input voltage inspection, note the following.
○Disconnect the main throttle sensor connector and connect the harness adapter [A] between these connectors. Special Tool - Throttle Sensor Setting Adapter: -1538
57001
Main Throttle Sensor Output Voltage Connections to Adapter: Digital Meter (+) → R (sensor Y/W) lead Digital Meter (–) → W (sensor BR/BK) lead
the engine and warm it up thoroughly. • Start Check idle speed to ensure the throttle opening is correct. • Idle Speed Standard:
1 300 ±50 r/min (rpm)
If the idle speed is out of the specified range, adjust it (see Idle Speed Adjustment in the Periodic Maintenance chapter). the ignition switch OFF. • Turn Measure the output voltage with the engine stopped and • with the connector joined. Turn the ignition switch ON. • Output Voltage Standard: DC 1.020 ∼ 1.050 V at idle throttle opening DC 4.185 ∼ 4.385 V at full throttle opening (for reference)
○Open
NOTE
the throttle, confirm the output voltage will be raise. ○The standard voltage refers to the value when the voltage reading at the Input Voltage Inspection shows 5 V exactly. ○When the input voltage reading shows other than 5 V, derive a voltage range as follows. Example: In the case of a input voltage of 4.75 V. 1.020 × 4.75 ÷ 5.00 = 0.969 V 1.050 × 4.75 ÷ 5.00 = 0.998 V Thus, the valid range is 0.969 ∼ 0.998 V the ignition switch OFF. • Turn If the reading is out of the standard, check the main throttle sensor resistance (see Main Throttle Sensor Resistance Inspection).
FUEL SYSTEM (DFI) 3-43 Main Throttle Sensor (Service Code 11) If the reading is within the standard, remove the ECU and check the wiring for continuity between main harness connectors. Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→ Main Throttle Sensor Connector [B] Y/W lead (ECU terminal 6) [C] BR/BK lead (ECU terminal 22) [D]
If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).
Main Throttle Sensor Resistance Inspection
the ignition switch OFF. • Turn Disconnect the main throttle sensor connector. • Connect a digital • connector [B]. meter [A] to the main throttle sensor • Measure the main throttle sensor resistance. Main Throttle Sensor Resistance Connections: BL lead [C] ←→ BR/BK lead [D] Standard:
4 ∼ 6 kΩ
If the reading is out of the standard, replace the throttle body assy (see Throttle Body Assy Removal/Installation). If the reading is within the standard, but the problem still exists, replace the ECU (see ECU Removal/Installation).
Main Throttle Sensor Circuit
1. ECU 2. Main Throttle Sensor 3. Water-proof Joint 2 4. Water-proof Joint 1
3-44 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) Inlet Air Pressure Sensor Removal CAUTION Never drop the inlet air pressure sensor especially on a hard surface. Such a shock to the sensor can damage it.
• Remove: Fuel Tank (see Fuel Tank Removal) Inlet Air Pressure Sensor Connector [A] (Disconnect) the inlet air pressure sensor [A] from the rubber • Remove damper of the air switching valve and separate the vacuum hose [B].
Inlet Air Pressure Sensor Installation
• Installation is the reverse of removal.
Inlet Air Pressure Sensor Input Voltage Inspection NOTE
○Be sure the battery is fully charged.
the ignition switch OFF. • Turn Remove fuel tank (see Fuel Tank Removal). • Disconnectthethe inlet air pressure sensor connector and • connect the harness adapter [A] between these connectors. Special Tool - Sensor Harness Adapter: 57001-1561
• Connect a digital meter to the harness adapter leads. Inlet Air Pressure Sensor Input Voltage Connections to Adapter: Digital Meter (+) → G (sensor BL) lead Digital Meter (–) → BK (sensor BR/BK) lead
the input voltage with the engine stopped and • Measure with the connector joined. • Turn the ignition switch ON. Input Voltage Standard: DC 4.75 ∼ 5.25 V
the ignition switch OFF. • Turn If the reading is within the standard, check the output voltage (see Inlet Air Pressure Sensor Output Voltage Inspection).
FUEL SYSTEM (DFI) 3-45 Inlet Air Pressure Sensor (Service Code 12) If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→ Inlet Air Pressure Sensor Connector [B] BL lead (ECU terminal 8) [C] BR/BK lead (ECU terminal 22) [D]
If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).
Inlet Air Pressure Sensor Output Voltage Inspection
the output voltage at the inlet air pressure sen• Measure sor in the same way as input voltage inspection, note the following. ○Disconnect the inlet air pressure sensor connector and connect the harness adapter [A] between these connectors. Special Tool - Sensor Harness Adapter: 57001-1561 Inlet Air Pressure Sensor Output Voltage Connections to Adapter: Digital Meter (+) → G/W (sensor Y/BL) lead Digital Meter (–) → BK (sensor BR/BK) lead
the output voltage with the engine stopped and • Measure with the connector joined. • Turn the ignition switch ON. Output Voltage Usable Range:
DC 3.80 ∼ 4.20 V at standard atmospheric pressure (101.32 kPa, 76 cmHg)
NOTE
○The output voltage changes according to local atmospheric pressure.
the ignition switch OFF. • Turn If the reading is out of the usable range, replace the sensor.
3-46 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12) If the reading is within the usable range, remove the ECU and check the wiring for continuity between main harness connector. Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→ Inlet Air Pressure Sensor Connector [B] Y/BL lead (ECU terminal 7) [C] BR/BK lead (ECU terminal 22) [D]
If the wiring is good, check the sensor for various vacuum. Remove the inlet air pressure sensor [A] and disconnect the vacuum hose from the sensor. Connect an auxiliary hose [B] to the inlet air pressure sensor. Temporarily install the inlet air pressure sensor. ○Connect a digital meter [C], vacuum gauge [D], the fork oil level gauge [E] and the harness adapter to the inlet air pressure sensor.
• • •
Special Tools - Fork Oil Level Gauge: 57001-1290 Vacuum Gauge: 57001-1369 Sensor Harness Adapter: 57001-1561 Inlet Air Pressure Sensor Output Voltage Connections to Adapter: Digital Meter (+) → G/W (sensor Y/BL) lead Digital Meter (–) → BK (sensor BR/BK) lead
○Turn the ignition switch ON. ○Measure the inlet air pressure sensor output voltage from various vacuum readings, while pulling the handle of the fork oil level gauge. ○Check the inlet air pressure sensor output voltage, using the following formula and chart. Suppose: Pg: Vacuum Pressure (Gauge) of Throttle Body Pl: Local Atmospheric Pressure (Absolute) measured by a barometer Pv: Vacuum Pressure (Absolute) of Throttle Body Vv: Sensor Output Voltage (V)
FUEL SYSTEM (DFI) 3-47 Inlet Air Pressure Sensor (Service Code 12) then Pv = Pl – Pg For example, suppose the following data is obtained: Pg = 8 cmHg (Vacuum Gauge Reading) Pl = 70 cmHg (Barometer Reading) Vv = 3.2 V (Digital Meter Reading) then Pv = 70 – 8 = 62 cmHg (Absolute) Plot this Pv (62 cmHg) at a point [1] on the chart and draw a vertical line through the point. Then, you can get the usable range [2] of the sensor output voltage. Usable range = 3.08 ∼ 3.48 V Plot Vv (3.2 V) on the vertical line. → Point [3]. Results: In the chart, Vv is within the usable range and the sensor is normal. If the reading is out of the usable range, replace the sensor. If the reading is within the usable range, check the ECU for its ground and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).
3-48 FUEL SYSTEM (DFI) Inlet Air Pressure Sensor (Service Code 12)
ID: Idling Ps: Standard Atmospheric Pressure (Absolute) Pv: Throttle Vacuum Pressure (Absolute) ST: Standard of Sensor Output Voltage (V) TO: Throttle Full Open UR: Usable Range of Sensor Output Voltage (V) Vv: Inlet Air Pressure Sensor Output Voltage (V) (Digital Meter Reading)
FUEL SYSTEM (DFI) 3-49 Inlet Air Pressure Sensor (Service Code 12) Inlet Air Pressure Sensor Circuit
1. ECU 2. Water-proof Joint 2 3. Inlet Air Pressure Sensor 4. Water-proof Joint 1
3-50 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code 13) Inlet Air Temperature Sensor Removal/Installation CAUTION Never drop the inlet air temperature sensor especially on a hard surface. Such a shock to the sensor can damage it.
• Remove: Fuel Tank (see Fuel Tank Removal) Inlet Air Temperature Sensor Connector [A] (Disconnect) Inlet Air Temperature Sensor Screw [B] Inlet Air Temperature Sensor [C] the inlet air temperature sensor [A] into the air cleaner • Put housing [B]. • Tighten:
Torque - Inlet Air Temperature Sensor Screw: 1.2 N·m (0.12 kgf·m, 11 in·lb)
Inlet Air Temperature Sensor Output Voltage Inspection NOTE
○Be sure the battery is fully charged.
the ignition switch OFF. • Turn Remove fuel tank (see Fuel Tank Removal). • Disconnectthethe air temperature sensor connector • and connect theinletharness adapter [A] between these connectors as shown in the figure. Main Harness [B] Inlet Air Temperature Sensor [C] Special Tool - Measuring Adapter: 57001-1700
• Connect a digital meter [D] to the harness adapter leads. Inlet Air Temperature Sensor Output Voltage Connections to Adapter: Digital Meter (+) → R (sensor Y) lead Digital Meter (–) → BK (sensor BR/BK) lead
the output voltage with the engine stopped and • Measure the connector joined. • Turn the ignition switch ON. Output Voltage Standard: About DC 2.25 ∼ 2.50 V at inlet air temperature 20°C (68°F)
NOTE
○The output voltage changes according to the inlet air temperature.
FUEL SYSTEM (DFI) 3-51 Inlet Air Temperature Sensor (Service Code 13) the ignition switch OFF. • Turn If the reading is within the standard, check the ECU for its ground and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation). If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness side connectors. Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→ Inlet Air Temperature Sensor Connector [B] Y lead (ECU terminal 20) [C] BR/BK lead (ECU terminal 22) [D]
If the wiring is good, check the inlet air temperature sensor resistance (see Inlet Air Temperature Sensor Resistance Inspection).
Inlet Air Temperature Sensor Resistance Inspection
the inlet air temperature sensor (see Inlet Air • Remove Temperature Sensor Removal/Installation). the sensor [A] in a container of machine oil so • Suspend that the heat-sensitive portion is submerged. a thermometer [B] with the heat-sensitive por• Suspend tion [C] located in almost the same depth with the sensor.
NOTE
○The sensor and thermometer must not touch the container side or bottom.
the container over a source of heat and gradually • Place raise the temperature of the oil while stirring the oil gently
•
for even temperature. Using a digital meter, measure the internal resistance of the sensor across the terminals at the temperatures shown in the following. Inlet Air Temperature Sensor Resistance Standard: 5.4 ∼ 6.6 kΩ at 0°C (32°F) 0.29 ∼ 0.39 kΩ at 80°C (176°F)
If the reading is out of the standard, replace the sensor. If the reading is within the standard, but the problem still exists, replace the ECU (see ECU Removal/Installation).
3-52 FUEL SYSTEM (DFI) Inlet Air Temperature Sensor (Service Code 13) Inlet Air Temperature Sensor Circuit
1. ECU 2. Water-proof Joint 1 3. Inlet Air Temperature Sensor
FUEL SYSTEM (DFI) 3-53 Water Temperature Sensor (Service Code 14) Water Temperature Sensor Removal/Installation CAUTION Never drop the water temperature sensor especially on a hard surface. Such a shock to the sensor can damage it.
• Remove: Coolant (Drain, •
see Coolant Change in the Periodic Maintenance chapter) Connector [A] (Disconnect) Water Temperature Sensor [B] Replace the gasket with a new one, and tighten the water temperature sensor. Torque - Water Temperature Sensor: 25 N·m (2.5 kgf·m, 18 ft·lb)
the engine with coolant and bleed the air from the cool• Fill ing system (see Coolant Change in the Periodic Maintenance chapter).
Water Temperature Sensor Output Voltage Inspection NOTE
○Be sure the battery is fully charged.
the ignition switch OFF. • Turn Remove tank (see Fuel Tank Removal). • Disconnectthethefuelwater temperature sensor connector and • connect the harness adapter [A] between these connectors as shown in the figure. Main Harness [B] Water Temperature Sensor [C] Special Tool - Measuring Adapter: 57001-1700
• Connect a digital meter [D] to the harness adapter leads. Water Temperature Sensor Output Voltage Connections to Adapter: Digital Meter (+) → R (sensor O) lead Digital Meter (–) → BK (sensor BR/BK) lead
the output voltage with the engine stopped and • Measure with the connector joined. • Turn the ignition switch ON. Output Voltage Standard: About DC 2.80 ∼ 2.97 V at 20°C (68°F)
NOTE
○The output voltage changes according to the coolant temperature in the engine. the ignition switch OFF. • Turn If the reading is within the standard, check the ECU for its ground and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).
3-54 FUEL SYSTEM (DFI) Water Temperature Sensor (Service Code 14) If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→ Water Temperature Sensor Connector [B] O lead (ECU terminal 17) [C] BR/BK lead (ECU terminal 22) [D]
If the wiring is good, check the water temperature sensor resistance (see Water Temperature Sensor Resistance Inspection).
Water Temperature Sensor Resistance Inspection
to the Water Temperature Sensor Inspection in the • Refer Electrical System chapter. If the reading is within the standard, but the problem still exists, replace the ECU (see ECU Removal/Installation).
Water Temperature Sensor Circuit
1. ECU 2. Water-proof Joint 1 3. Water Temperature Sensor
FUEL SYSTEM (DFI) 3-55 Crankshaft Sensor (Service Code 21) The crankshaft sensor has no power source, and when the engine stops, the crankshaft sensor generates no signals.
Crankshaft Sensor Removal/Installation
to the Crankshaft Sensor Removal/Installation in • Refer the Electrical System chapter.
Crankshaft Sensor Resistance Inspection
to the Crankshaft Sensor Inspection in the Electrical • Refer System chapter. If the reading is within the standard, check the peak voltage (see Crankshaft Sensor Peak Voltage Inspection).
Crankshaft Sensor Peak Voltage Inspection
to the Crankshaft Sensor Peak Voltage Inspection • Refer in the Electrical System chapter. If the reading is within the standard, remove the ECU and check the wiring for continuity between main harness connectors. Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→ Crankshaft Sensor Connector [B] R/BK lead (ECU terminal 11) [C] Y/BK lead (ECU terminal 24) [D]
If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).
Crankshaft Sensor Circuit
1. ECU 2. Crankshaft Sensor
3-56 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24, 25) Speed Sensor Removal/Installation
to the Speed Sensor Removal/Installation in the • Refer Electrical System chapter.
Speed Sensor Inspection
to the Speed Sensor Inspection in the Electrical • Refer System chapter.
Speed Sensor Input Voltage Inspection NOTE
○Be sure the battery is fully charged.
the ignition switch OFF. • Turn Remove left side cover (see Side Cover Removal in • the Framethechapter). the speed sensor connector and connect the • Disconnect harness adapter [A] between these connectors. Special Tool - Throttle Sensor Setting Adapter #1: 57001 -1400
• Connect a digital meter to the harness adapter leads. Speed Sensor Input Voltage Connections to Adapter: Digital Meter (+) → BL (sensor P) lead Digital Meter (–) → BK/W (sensor BK) lead
the input voltage with the engine stopped and • Measure with the connector joined. • Turn the ignition switch ON. Input Voltage Standard: DC 4.75 ∼ 5.25 V
the ignition switch OFF. • Turn If the reading is within the standard, check the output voltage (see Speed Sensor Output Voltage Inspection). If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→ Speed Sensor Connector [B] BL lead (ECU terminal 8) [C] BR/BK lead (ECU terminal 22) [D]
If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).
FUEL SYSTEM (DFI) 3-57 Speed Sensor (Service Code 24, 25) Speed Sensor Output Voltage Inspection
the rear wheel off the ground with the stand. • Raise Measure output voltage at the speed sensor in the • same waythe as input voltage inspection, note the following.
○Disconnect the speed sensor connector and connect the harness adapter [A] between these connectors.
Special Tool - Throttle Sensor Setting Adapter #1: 57001 -1400 Speed Sensor Output Voltage Connections to Adapter: Digital Meter (+) → Y/W (sensor Y) lead Digital Meter (–) → BK/W (sensor BK) lead
the output voltage with the engine stopped and • Measure with the connector joined. • Turn the ignition switch ON. Output Voltage Standard: About DC 0.05 ∼ 0.09 V or DC 4.5 ∼ 4.9 V at ignition switch ON and 0 km/h
NOTE
○Rotate the rear wheel by hand, confirm the output voltage will be raise or lower.
the ignition switch OFF. • Turn If the reading is out of the standard, replace the sensor. If the reading is within the standard, remove the ECU and check the wiring for continuity between main harness connectors. Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→ Speed Sensor Connector [B] LG/R lead (ECU terminal 5) [C] BR/BK lead (ECU terminal 22) [D]
If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).
3-58 FUEL SYSTEM (DFI) Speed Sensor (Service Code 24, 25) Speed Sensor Circuit
1. ECU 2. Speed Sensor 3. Water-proof Joint 2 4. Water-proof Joint 1
FUEL SYSTEM (DFI) 3-59 Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Removal CAUTION Never drop the vehicle-down sensor especially on a hard surface. Such a shock to the sensor can damage it.
• Remove: Fuel Tank (see Fuel Tank Removal) Connector [A] (Disconnect) Vehicle-down Sensor [B]
Vehicle-down Sensor Installation
• The UPPER mark [A] of the sensor should face upward. WARNING
Incorrect installation of the vehicle-down sensor could cause sudden loss of engine power. The rider could lose balance during certain riding situations, like leaning over in a turn, with the potential for an accident resulting in injury or death. Ensure that the vehicle-down sensor is held in place by the sensor bracket.
Vehicle-down Sensor Input Voltage Inspection NOTE
○Be sure the battery is fully charged.
the ignition switch OFF. • Turn the fuel tank (see Fuel Tank Removal). • Remove Disconnect the vehicle-down sensor connector and con• nect the harness adapter [A] between these connectors as shown in the figure. Main Harness [B] Vehicle-down Sensor [C] Special Tool - Measuring Adapter: 57001-1700
• Connect a digital meter [D] to the harness adapter leads. Vehicle-down Sensor Input Voltage Connections to Adapter: Digital Meter (+) → R (sensor BL) lead Digital Meter (–) → BK (sensor BR/BK) lead
the input voltage with the engine stopped and • Measure with the connector joined. • Turn the ignition switch ON. Input Voltage Standard: DC 4.75 ∼ 5.25 V
the ignition switch OFF. • Turn If the reading is within the standard, check the output voltage (see Vehicle-down Sensor Output Voltage Inspection).
3-60 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→ Vehicle-down Sensor Connector [B] BL lead (ECU terminal 8) [C] BR/BK lead (ECU terminal 22) [D]
If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).
Vehicle-down Sensor Output Voltage Inspection
the vehicle-down sensor (see Vehicle-down • Remove Sensor Removal). the harness adapter [A] to the vehicle-down sen• Connect sor connectors as shown in the figure. Special Tool - Measuring Adapter: 57001-1700
•
Main Harness [B] Vehicle-down Sensor [C] Connect a digital meter [D] to the harness adapter leads. Vehicle-down Sensor Output Voltage Connections to Adapter: Digital Meter (+) → W (sensor Y/G) lead Digital Meter (–) → BK (sensor BR/BK) lead
FUEL SYSTEM (DFI) 3-61 Vehicle-down Sensor (Service Code 31) the sensor vertically. • Hold Measure the output voltage with the engine stopped and • with the connector joined. the ignition switch ON. • Turn Tilt the sensor 55 ∼ 75° or more [A] right or left, then hold • the sensor almost vertical with the arrow mark pointed up [B], and measure the output voltage. Output Voltage Standard: With sensor tilted 55 ∼ 75° or more right or left: DC 3.7 ∼ 4.4 V With sensor arrow mark pointed up: DC 0.4 ∼ 1.4 V
NOTE
○If you need to test again, turn the ignition switch OFF, and then ON.
the ignition switch OFF. • Turn If the reading is out of the standard, replace the sensor.
If the reading is within the standard, remove the ECU and check the wiring for continuity between main harness connectors. Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→ Vehicle-down Sensor Connector [B] Y/G lead (ECU terminal 9) [C] BR/BK lead (ECU terminal 22) [D]
If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).
3-62 FUEL SYSTEM (DFI) Vehicle-down Sensor (Service Code 31) Vehicle-down Sensor Circuit
1. ECU 2. Water-proof Joint 2 3. Vehicle-down Sensor 4. Water-proof Joint 1
FUEL SYSTEM (DFI) 3-63 Subthrottle Sensor (Service Code 32) Subthrottle Sensor Removal/Adjustment CAUTION Do not remove or adjust the subthrottle sensor [A] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy especially on a hard surface. Such a shock to the subthrottle sensor can damage it.
Subthrottle Sensor Input Voltage Inspection NOTE
○Be sure the battery is fully charged.
the ignition switch OFF. • Turn Disconnect sensor and connect the har• ness adapterthe[A]subthrottle between these connectors. Special Tool - Throttle Sensor Setting Adapter: -1538
57001
• Connect a digital meter to the harness adapter leads. Subthrottle Sensor Input Voltage Connections to Adapter: Digital Meter (+) → BK (sensor BL) lead Digital Meter (–) → W (sensor BR/BK) lead
the input voltage with the engine stopped and • Measure with the connector joined. • Turn the ignition switch ON. Input Voltage Standard: DC 4.75 ∼ 5.25 V
the ignition switch OFF. • Turn If the reading is within the standard, check the output voltage (see Subthrottle Sensor Output Voltage Inspection). If the reading is out of the standard, remove the ECU and check the wiring for continuity between main harness connectors. Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→ Subthrottle Sensor Connector [B] BL lead (ECU terminal 8) [C] BR/BK lead (ECU terminal 22) [D]
If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).
3-64 FUEL SYSTEM (DFI) Subthrottle Sensor (Service Code 32) Subthrottle Sensor Output Voltage Inspection
the output voltage at the subthrottle sensor in • Measure the same way as input voltage inspection, note the following.
○Disconnect the subthrottle sensor connector and connect the harness adapter [A] between these connectors. Special Tool - Throttle Sensor Setting Adapter: -1538
57001
Subthrottle Sensor Output Voltage Connections to Adapter: Digital Meter (+) → R (sensor BL/W) lead Digital Meter (–) → W (sensor BR/BK) lead
the fuel tank (see Fuel Tank Removal). • Remove Disconnect • nector [A]. the subthrottle valve actuator harness con-
the output voltage with the engine stopped with • Measure the connector joined. the ignition switch ON. • Turn Measure output voltage when the subthrottle valve is • completelytheclosed by turning the lever [A] fully clockwise [B]. Output Voltage Standard: DC 0.78 ∼ 0.82 V at subthrottle valve full close position DC 3.9 ∼ 4.1 V at subthrottle valve full open position (for reference)
NOTE
○Turn the lever counterclockwise, confirm the output volt-
age will be raise. ○The standard voltage refers to the value when the voltage reading at the Input Voltage Inspection shows 5 V exactly. ○When the input voltage reading shows other than 5 V, derive a voltage range as follows. Example: In the case of a input voltage of 4.75 V. 0.78 × 4.75 ÷ 5.00 = 0.741 V 0.82 × 4.75 ÷ 5.00 = 0.779 V Thus, the valid range is 0.741 ∼ 0.779 V the ignition switch OFF. • Turn If the reading is out of the standard, check the subthrottle sensor resistance (see Subthrottle Sensor Resistance Inspection).
FUEL SYSTEM (DFI) 3-65 Subthrottle Sensor (Service Code 32) If the reading is within the standard, remove the ECU and check the wiring for continuity between main harness connectors. Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→ Subthrottle Sensor Connector [B] BL/W lead (ECU terminal 19) [C] BR/BK lead (ECU terminal 22) [D]
If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).
Subthrottle Sensor Resistance Inspection
the ignition switch OFF. • Turn the subthrottle sensor connector. • Disconnect Connect a digital meter [A] to the subthrottle sensor con• nector [B]. • Measure the subthrottle sensor resistance. Subthrottle Sensor Resistance Connections: BL lead [C] ←→ BR/BK lead [D] Standard:
4 ∼ 6 kΩ
If the reading is out of the standard, replace the throttle body assy (see Throttle Body Assy Removal/Installation). If the reading is within the standard, but the problem still exists, replace the ECU (see ECU Removal/Installation).
Subthrottle Sensor Circuit
1. ECU 2. Subthrottle Sensor 3. Water-proof Joint 2 4. Water-proof Joint 1
3-66 FUEL SYSTEM (DFI) Oxygen Sensor - not activated (Service Code 33) Oxygen Sensor Removal/Installation
to the Oxygen Sensor Removal/Installation in the • Refer Electrical System chapter.
Oxygen Sensor Inspection
up the engine thoroughly until the radiator fan • Warm starts. the ignition switch OFF. • Turn the right lower fairing (see Lower Fairing Re• Remove moval in the Frame chapter). the oxygen sensor lead connector and con• Disconnect nect the harness adapter [A] between these connectors. Special Tool - Oxygen Sensor Measuring Adapter: 57001 -1682
• Connect a digital meter to the harness adapter leads. Oxygen Sensor Output Voltage Connections to Adapter: Digital Meter (+) → BL/W (sensor BL) lead Digital Meter (−) → BR/BK (sensor W) lead
the fuel tank (see Fuel Tank Removal). • Remove Separate the hose [A] from the air cleaner housing. •
• Separate the hose [A] from the air suction valve cover.
○Do not disconnect the air switching valve connector [A].
FUEL SYSTEM (DFI) 3-67 Oxygen Sensor - not activated (Service Code 33) the suitable plug [A] on the fitting of the air suction • Install valve cover, and shut off the secondary air. • Install the fuel tank (see Fuel Tank Installation).
the engine, and let it idle. • Start Measure the output voltage with the connector joined. • Output Voltage (with Plug) Standard: DC 0.7 V or more
remove the plug from the fitting [A] with idling. • Next, Measure the output voltage with the connector joined. • Output Voltage (without Plug) Standard: DC 0.2 V or less
• Turn the ignition switch OFF.
If the reading is out of the standard (with plug: DC 0.7 V or more, without plug: DC 0.2 V or less), remove the ECU and check the wiring for continuity between main harness connectors. Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→ Oxygen Sensor Connector [B] BL/Y lead (ECU terminal 4) [C] BR/BK lead (ECU terminal 22) [D]
If the wiring is good, replace the sensor. If the reading is within the standard (with plug: DC 0.7 V or more, without plugs: DC 0.2 V or less), check the ECU for its ground and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).
3-68 FUEL SYSTEM (DFI) Oxygen Sensor - not activated (Service Code 33) Oxygen Sensor Circuit
1. Ignition Switch 2. Water-proof Joint 3 3. Water-proof Joint 1 4. Oxygen Sensor 5. ECU 6. Joint Connector 2 7. Battery 12 V 8 Ah 8. Frame Ground 9. Main Fuse 30 A 10. Oxygen Sensor Heater Fuse 10 A 11. Fuse Box
FUEL SYSTEM (DFI) 3-69 Stick Coils #1, #2 (Service Code 51, 52) Stick Coil #1: Service Code 51 Stick Coil #2: Service Code 52
Stick Coil Removal/Installation
to the Stick Coil Removal/Installation in the Electri• Refer cal System chapter.
Stick Coil Primary Winding Resistance Inspection
to the Stick Coil Inspection in the Electrical System • Refer chapter. If the reading is within the standard, check the input voltage (see Stick Coil Input Voltage Inspection).
Stick Coil Input Voltage Inspection NOTE
○Be sure the battery is fully charged.
the ignition switch OFF. • Turn the ECU (see ECU Removal). •○Remove Do not disconnect the ECU connectors. a digital meter [A] to the connector [B] with the • Connect needle adapter set. Special Tool - Needle Adapter Set: 57001-1457 Stick Coil Input Voltage Connections to ECU Connector: For Stick Coil #1 Digital Meter (+) → BK lead (terminal 35) Digital Meter (–) → BK/Y lead (terminal 43) For Stick Coil #2 Digital Meter (+) → BK/G lead (terminal 44) Digital Meter (–) → BK/Y lead (terminal 43)
the input voltage to each primary winding of the • Measure stick coils with the engine stopped and with the connec-
• •
tors joined. Turn the engine stop switch to run position. Turn the ignition switch ON. Input Voltage Standard: Battery Voltage
the ignition switch OFF. • Turn If the input voltage is out of the standard, check the wiring for continuity (see wiring diagram in this section). If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation). If the input voltage is within the standard, check the ECU for its ground and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).
3-70 FUEL SYSTEM (DFI) Stick Coils #1, #2 (Service Code 51, 52) Stick Coil Circuit
1. Engine Stop Switch 2. Stick Coil #1, #2 3. Water-proof Joint 3 4. ECU 5. Joint Connector 2 6. Battery 12 V 8 Ah 7. Frame Ground 8. Main Fuse 30 A 9. Ignition Fuse 10 A 10. Fuse Box 11. Ignition Switch
FUEL SYSTEM (DFI) 3-71 Radiator Fan Relay (Service Code 56) Radiator Fan Relay Removal/Installation
○The radiator fan relay is built in the relay box [A].
to the Relay Box Removal in the Electrical System • Refer chapter.
Radiator Fan Relay Inspection
to the Relay Circuit Inspection in the Electrical Sys• Refer tem chapter. If the radiator fan relay is normal, check the wiring for continuity (see wiring diagram in this section). If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).
3-72 FUEL SYSTEM (DFI) Radiator Fan Relay (Service Code 56) Radiator Fan Relay Circuit
1. ECU 2. Joint Connector 2 3. Battery 12 V 8 Ah 4. Frame Ground 5. Main Fuse 30 A 6. Joint Connector 1 7. Relay Box 8. Fan Relay 9. ECU Fuse 15 A 10. Fan Fuse 10 A 11. Fuse Box 12. Resistor 13. Fan Motor 14. Water-proof Joint 3 15. Water-proof Joint 1 16. Water Temperature Sensor
FUEL SYSTEM (DFI) 3-73 Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Removal CAUTION Do not remove the subthrottle valve actuator [A] since it has been adjusted and set with precision at the factory. Never drop the throttle body assy especially on a hard surface. Such a shock to the subthrottle valve actuator can damage it.
Subthrottle Valve Actuator Inspection NOTE
○Be sure the battery is fully charged.
the throttle body assy (see Throttle Body Assy • Remove Removal). the following parts temporary. • Connect Main Throttle Sensor Connector [A]
• • •
Subthrottle Sensor Connector [B] Subthrottle Valve Actuator Connector [C] Turn the ignition switch ON. Check to see that all the subthrottle valves [D] open and close smoothly. Turn the ignition switch OFF. If the subthrottle valves do not operate, check the subthrottle valve actuator resistance (see Subthrottle Valve Actuator Resistance Inspection).
Subthrottle Valve Actuator Resistance Inspection the ignition switch OFF. • Turn Remove tank (see Fuel Tank Removal). • Disconnectthethefuelsubthrottle valve actuator connector [A]. •
a digital meter to the subthrottle valve actuator • Connect connector [A]. • Measure the subthrottle valve actuator resistance. Subthrottle Valve Actuator Resistance Connections: BK lead [1] ←→ P lead [2] G lead [3] ←→ W/BL lead [4] Standard:
About 5.2 ∼ 7.8 Ω
If the reading is out of the standard, replace the throttle body assy (see Throttle Body Assy Removal/Installation). If the reading is within the standard, check the input voltage (see Subthrottle Valve Actuator Input Voltage Inspection).
3-74 FUEL SYSTEM (DFI) Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Input Voltage Inspection NOTE
○Be sure the battery is fully charged.
the ignition switch OFF. • Turn Disconnect subthrottle valve actuator connector and • connect the the harness adapter [A] between these connectors as shown in the figure. Main Harness [B] Subthrottle Valve Actuator [C] Special Tool - Measuring Adapter: 57001-1700
the peak voltage adapter [D] and a digital meter • Connect [E] to the harness adapter leads. Special Tool - Peak Voltage Adapter: 57001-1415 Type: KEK-54-9-B Subthrottle Valve Actuator Input Voltage Connections to Adapter: (I) Digital Meter (+) → R (actuator P) lead Digital Meter (–) → BK (actuator BK) lead (II) Digital Meter (+) → W (actuator W/BL) lead Digital Meter (–) → Y (actuator G) lead
the actuator input voltage with • Measure stopped and with the connector joined. • Turn the ignition switch ON.
the engine
Input Voltage Standard: About DC 11.5 ∼ 13.5 V
the ignition switch OFF. • Turn If the reading is in specification, but the actuator does not operate, replace the throttle body assy (see Throttle Body Assy Removal/Installation). If the reading is out of the specification, remove the ECU and check the wiring for continuity between main harness connectors. Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and actuator connectors. Wiring Continuity Inspection ECU Connector [A] ←→ Subthrottle Valve Actuator Connector [B] W/BL lead (ECU terminal 1) [C] P lead (ECU terminal 2) [D] G/Y lead (ECU terminal 14) [E] BK/BL lead (ECU terminal 15) [F]
If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).
FUEL SYSTEM (DFI) 3-75 Subthrottle Valve Actuator (Service Code 62) Subthrottle Valve Actuator Circuit
1. ECU 2. Subthrottle Valve Actuator
3-76 FUEL SYSTEM (DFI) Air Switching Valve (Service Code 64) Air Switching Valve Removal/Installation
to the Air Switching Valve Removal/Installation in • Refer the Engine Top End chapter.
Air Switching Valve Inspection
to the Air Switching Valve Unit Test in the Electrical • Refer System chapter. If the air switching valve is normal, check the wiring for continuity (see wiring diagram in this section). If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).
Air Switching Valve Circuit
1. ECU 2. Joint Connector 2 3. Battery 12 V 8 Ah 4. Frame Ground 5. Main Fuse 30 A 6. Relay Box
7. ECU Main Relay 8. ECU Fuse 15 A 9. Fuse Box 10. Ignition Switch 11. Water-proof Joint 3 12. Air Switching Valve
FUEL SYSTEM (DFI) 3-77 Oxygen Sensor Heater (Service Code 67) Oxygen Sensor Heater Removal/Installation The oxygen sensor heater is built in the oxygen sensor. So, the heater itself can not be removed. Remove the oxygen sensor (see Oxygen Sensor Removal in the Electrical System chapter).
Oxygen Sensor Heater Resistance Inspection
the ignition switch OFF. • Turn the right lower fairing (see Lower Fairing Re• Remove moval in the Frame chapter). • Disconnect the oxygen sensor lead connector [A].
a digital meter [A] to the oxygen sensor lead con• Connect nector [B]. • Measure the oxygen sensor heater resistance. Oxygen Sensor Heater Resistance Connections: BK lead [C] ←→ BK lead [D] Standard: 11.7 ∼ 15.5 Ω at 20°C (68°F)
If the reading is out of the standard, replace the sensor. If the reading is within the standard, check the power source voltage (see Oxygen Sensor Heater Power Source Voltage Inspection).
Oxygen Sensor Heater Power Source Voltage Inspection NOTE
○Be sure the battery is fully charged.
the ignition switch OFF. • Turn Disconnect the oxygen sensor lead connector and con• nect the harness adapter [A] between these connectors. Special Tool - Oxygen Sensor Measuring Adapter: 57001 -1682
• Connect a digital meter to the harness adapter lead. Oxygen Sensor Power Source Voltage Connections to Adapter: Digital Meter (+) → P/Y (sensor BK) lead Digital Meter (–) → Battery (–) terminal
the power source voltage with • Measure stopped and with the connector joined. • Turn the ignition switch ON.
the engine
Power Source Voltage Standard: Battery Voltage
the ignition switch OFF. • Turn If the reading is in specification, but the problem still exists, replace the ECU (see ECU Removal/Installation). If the reading is out of the standard, check the following. Oxygen Sensor Heater Fuse 10 A (see Fuse Inspection in the Electrical System chapter) Power Source Wiring (see wiring diagram in this section)
3-78 FUEL SYSTEM (DFI) Oxygen Sensor Heater (Service Code 67) If the fuse and wiring are good, remove the ECU and check the wiring for continuity between main harness connectors. Special Tool - Hand Tester: 57001-1394
○Disconnect the ECU and sensor connectors. Wiring Continuity Inspection ECU Connector [A] ←→ Oxygen Sensor Connector [B] P/BK lead (ECU terminal 23) [C]
If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).
Oxygen Sensor Circuit
1. Ignition Switch 2. Water-proof Joint 3 3. Water-proof Joint 1 4. Oxygen Sensor 5. ECU 6. Joint Connector 2 7. Battery 12 V 8 Ah 8. Frame Ground 9. Main Fuse 30 A 10. Oxygen Sensor Heater Fuse 10 A 11. Fuse Box
FUEL SYSTEM (DFI) 3-79 Oxygen Sensor - Incorrect Output Voltage (Service Code 94) Oxygen Sensor Removal/Installation
to the Oxygen Sensor Removal/Installation in the • Refer Electrical System chapter.
Oxygen Sensor Inspection
up the engine thoroughly until the radiator fan • Warm starts. the ignition switch OFF. • Turn the right lower fairing (see Lower Fairing Re• Remove moval in the Frame chapter). the oxygen sensor lead connector and con• Disconnect nect the harness adapter [A] between these connectors. Special Tool - Oxygen Sensor Measuring Adapter: 57001 -1682
• Connect a digital meter to the harness adapter leads. Oxygen Sensor Output Voltage Connections to Adapter: Digital Meter (+) → BL/W (sensor BL) lead Digital Meter (−) → BR/BK (sensor W) lead
the fuel tank (see Fuel Tank Removal). • Remove Separate the hose [A] from the air cleaner housing. •
• Separate the hose [A] from the air suction valve cover.
○Do not disconnect the air switching valve connector [A].
3-80 FUEL SYSTEM (DFI) Oxygen Sensor - Incorrect Output Voltage (Service Code 94) the suitable plug [A] on the fitting of the air suction • Install valve cover, and shut off the secondary air. • Install the fuel tank (see Fuel Tank Installation).
the engine, and let it idle. • Start Measure the output voltage with the connector joined. • Output Voltage (with Plug) Standard: DC 0.7 V or more
remove the plug from the fitting [A] with idling. • Next, Measure the output voltage with the connector joined. • Output Voltage (without Plug) Standard: DC 0.2 V or less
the ignition switch OFF. • Turn If the reading is out of the standard (with plug: DC 0.7 V or more, without plug: DC 0.2 V or less), check the following. Fuel Pressure (see Fuel Pressure Inspection) Fuel Injector (see Fuel Injectors section) If the fuel pressure and fuel injectors are good, replace the sensor. If the reading is within the standard (with plug: DC 0.7 V or more, without plug: DC 0.2 V or less), check the ECU for its ground and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).
FUEL SYSTEM (DFI) 3-81 Oxygen Sensor - Incorrect Output Voltage (Service Code 94) Oxygen Sensor Circuit
1. Ignition Switch 2. Water-proof Joint 3 3. Water-proof Joint 1 4. Oxygen Sensor 5. ECU 6. Joint Connector 2 7. Battery 12 V 8 Ah 8. Frame Ground 9. Main Fuse 30 A 10. Oxygen Sensor Heater Fuse 10 A 11. Fuse Box
3-82 FUEL SYSTEM (DFI) FI Indicator Light Light Inspection
to the Lights and Switches Operation Inspection in • Refer the Periodic Maintenance chapter.
FI Indicator Light Circuit
1. Ignition Switch 2. Water-proof Joint 3 3. ECU 4. Joint Connector 2 5. Battery 12 V 8 Ah 6. Frame Ground 7. Main Fuse 30 A 8. Ignition Fuse 10 A 9. Fuse Box 10. FI Indicator Light
FUEL SYSTEM (DFI) 3-83 ECU ECU Identification
○Most countries have their own regulations, so each ECU
has different characteristic. So, do not confuse ECU with each other and use only the ECU for your model. Otherwise, the motorcycle cannot clear the regulation.
ECU Identification Part Number [A] 21175-0199
Specification WVTA (FULL N) GB WVTA (FULL N)
ECU Removal CAUTION Never drop the ECU especially on a hard surface. Such a shock to the ECU can damage it.
• Remove: Seat Covers (see Seat Cover Removal in the Frame chapter) Bolts [A] Brackets [B]
• Lift up the ECU [A] with rubber protector [B].
• Remove: ECU Connectors [A] (Disconnect) ECU [B]
ECU Installation
• Install: ECU [A] (In Rubber Protector [B]) ECU Connectors [C] (Connect)
3-84 FUEL SYSTEM (DFI) ECU the slits of the rubber protector to the projections • Insert [A] of the rear fender.
ECU Power Supply Inspection
the front seat (see Front Seat Removal in the • Remove Frame chapter). inspect the ECU connectors. • Visually If the connector is clogged with mud or dust, blow it off
• •
with compressed air. Remove the ECU (see ECU Removal). Visually inspect the terminals [A] of the ECU connectors. If the terminals of the main harness connectors are damaged, replace the main harness. If the terminals of the ECU connectors are damaged, replace the ECU.
the ignition switch OFF. • Turn Disconnect ECU connectors [A]. • Set the handthetester [B] to the × 1 Ω range and check the • following wiring for continuity. Special Tool - Hand Tester: 57001-1394 ECU Grounding Continuity Inspection Connections: (I) BK/Y leads (ECU terminal 26, 42 or 43)
←→ Battery (–) Terminal
(II) Engine Ground
←→ Battery (–) Terminal
Criteria: Both: 0 Ω
If no continuity, check the connectors, the engine ground lead, or main harness, and repair or replace them if necessary.
FUEL SYSTEM (DFI) 3-85 ECU If the wiring is good, check the power source voltage of the ECU.
NOTE
○Be sure the battery is fully charged.
the ECU connectors. • Connect Connect a digital meter [A] to the connector [B] with the • needle adapter set. Special Tool - Needle Adapter Set: 57001-1457 ECU Power Supply Inspection Connections: (I) Digital Meter (+) → Terminal 12 (BR/W) Digital Meter (–) → Battery (–) terminal (II) Digital Meter (+) → Terminal 27 (W/BK) Digital Meter (–) → Battery (–) terminal Ignition Switch OFF: Terminal 12 (BR/W): 0 V Terminal 27 (W/BK): Battery Voltage Ignition Switch ON: Both: Battery Voltage
If the reading is out of the specification, check the following. Main Fuse 30 A (see Fuse Inspection in the Electrical System chapter) ECU Fuse 15 A (see Fuse Inspection in the Electrical System chapter) ECU Main Relay (see Relay Circuit Inspection in the Electrical System chapter) Power Source Wiring (see wiring diagram in this section ) If the fuse, wiring and relay are good, replace the ECU (see ECU Removal/Installation).
3-86 FUEL SYSTEM (DFI) ECU ECU Power Source Circuit
1. Ignition Switch 2. Water-proof Joint 3 3. ECU 4. Joint Connector 2 5. Battery 12 V 8 Ah 6. Frame Ground 7. Main Fuse 30 A 8. Relay Box 9. ECU Main Relay 10. ECU Fuse 15 A 11. Fuse Box
FUEL SYSTEM (DFI) 3-87 DFI Power Source ECU Fuse Removal
to the 15 A ECU Fuse Removal in the Electrical • Refer System chapter.
ECU Fuse Installation
•
If a fuse fails during operation, inspect the DFI system to determine the cause, and then replace it with a new fuse of proper amperage. Refer to the Fuse Installation in the Electrical System chapter.
ECU Fuse Inspection
to the Fuse Inspection in the Electrical System • Refer chapter.
ECU Main Relay Removal/Installation
○The ECU main relay is built in the relay box [A].
to the Relay Box Removal in the Electrical System • Refer chapter.
ECU Main Relay Inspection
to the Relay Circuit Inspection in the Electrical Sys• Refer tem chapter.
3-88 FUEL SYSTEM (DFI) Fuel Line Fuel Pressure Inspection NOTE
○Be sure the battery is fully charged.
• Remove: Fuel Tank (see Fuel Tank Removal)
Fuel Hose (see Fuel Hose Replacement in the Periodic Maintenance chapter) Be ○ sure to place a piece of cloth around the fuel supply pipes of the fuel pump and the throttle body assy.
WARNING Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe because of residual pressure. Cover the hose connection with a piece of clean cloth to prevent fuel spillage. the fuel pressure gauge adapter [A] and fuel hoses • Install (Special Tool: 57001-1607) [B] between the fuel supply
• •
pipes of the fuel pump and throttle body assy. Secure the fuel hoses with the clamps. Connect the pressure gauge [C] to the fuel pressure gauge adapter. Special Tools - Oil Pressure Gauge, 5 kgf/cm²: 57001-125 Fuel Pressure Gauge Adapter: 57001-1593 Fuel Hose: 57001-1607
WARNING Do not try to start the engine with the fuel hoses disconnected. the fuel pump lead connector. • Connect Turn the engine switch run position. • Turn the ignition stop switch ON. •○The fuel pump should operate for 3 seconds, and then should stop.
○After
NOTE
turning on the engine stop switch and ignition switch, inspect the fuel leakage from the connected portion of the special tools.
CAUTION Do not drive the fuel pump 3 seconds or more without the fuel in the fuel tank. If the fuel pump is driven without the fuel, it may be damaged. the engine, and let it idle. • Start Measure the fuel pressure with the engine idling. • Fuel Pressure (with Engine Idling) Standard: 294 kPa (3.0 kgf/cm², 43 psi)
FUEL SYSTEM (DFI) 3-89 Fuel Line NOTE
○The gauge needle will fluctuate.
Read the pressure at the average of the maximum and minimum indications.
the ignition switch OFF. • Turn If the fuel pressure is much higher than specified, replace
• • • •
the fuel pump because the fuel pressure regulator in the fuel pump have been clogged or stuck. If the fuel pressure is much lower than specified, check the following. Fuel Line Leakage (see Fuel Injector Fuel Line Inspection) Amount of Fuel Flow (see Fuel Flow Rate Inspection) After above checks, measure the fuel pressure again. Remove the fuel pressure gauge, hoses and adapter. Install: Fuel Hose (see Fuel Hose Replacement in the Periodic Maintenance chapter) Fuel Tank (see Fuel Tank Installation) Start the engine and check for fuel leakage.
Fuel Flow Rate Inspection
WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch OFF. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately.
NOTE
○Be sure the battery is fully charged.
the ignition switch OFF. • Turn until the engine cools down. • Wait Prepare hose (Special Tool: • measuringa fuel cylinder.
57001-1607) and a
Special Tool - Fuel Hose: 57001-1607
• Remove the fuel tank bolts (see Fuel Tank Removal). the fuel tank cap [A] to lower the pressure in the • Open tank. the fuel hose from the fuel pump (see Fuel Tank • Remove Removal). ○Be sure to place a piece of cloth around the fuel supply pipe of the fuel pump.
WARNING Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe because of residual pressure. Cover the hose connection with a piece of clean cloth to prevent fuel spillage.
3-90 FUEL SYSTEM (DFI) Fuel Line the prepared fuel hose [A] to the fuel supply pipe • Connect of the fuel pump. the fuel hose with a clamp. • Secure • Insert the fuel hose into the measuring cylinder [B].
WARNING
Wipe off spilled out fuel immediately. Be sure to hold the measuring cylinder vertical. the fuel tank cap. • Close Turn the stop switch to run position. • Turn the engine switch ON. •○The fuel ignition pump should operate for 3 seconds, and then should stop.
CAUTION Do not drive the fuel pump 3 seconds or more without the fuel in the fuel tank. If the fuel pump is driven without the fuel, it may be damaged. the discharge for 3 seconds. •○Measure Repeat this operation several times. Amount of Fuel Flow Standard: 17 mL (0.57 US oz.) or more for 3 seconds
the ignition switch OFF. • Turn If the fuel flow is much less than the specified, replace the
• •
fuel pump (see Fuel Pump Removal/Installation). Install the fuel tank (see Fuel Tank Installation). Start the engine and check for fuel leakage.
FUEL SYSTEM (DFI) 3-91 Fuel Pump Fuel Pump Removal
WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch OFF and disconnect the battery (–) terminal. To make fuel spillage minimum, draw the fuel out from the fuel tank when the engine is cold. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately.
CAUTION Never drop the fuel pump especially on a hard surface. Such a shock to the pump can damage it. the fuel out from the fuel tank with a commercially • Draw available electric pump. the fuel tank (see Fuel Tank Removal). •○Remove Be careful of fuel spillage from the fuel tank since fuel still remains in the fuel tank and fuel pump. Plug the fuel supply pipe of the fuel pump.
the fuel tank upside down. • Turn Free the lead from the clamp [A]. • Unscrew • pump [C].the fuel pump bolts [B], and take out the fuel
CAUTION Do not pull the lead of the fuel pump. If they are pulled, the lead terminals may be damaged.
• Discard the fuel pump gasket [A].
3-92 FUEL SYSTEM (DFI) Fuel Pump Fuel Pump Installation
dirt or dust from the fuel pump [A] by lightly ap• Remove plying compressed air. • Replace the fuel pump gasket with a new one.
a non-permanent locking agent to the threads of • Apply the fuel pump bolts. the fuel pump bolts to a snug fit, tighten them • Tighten alternating diagonally. Torque - Fuel Pump Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
the pump bolts again alternating diagonally to • Tighten check the tightness. • Hold the lead [A] with the clamp [B].
Fuel Pump Operation Inspection NOTE
○Be sure the battery is fully charged.
the engine stop switch to run position. • Turn the ignition switch ON and make sure that the fuel • Turn pump operates (make light sounds) for 3 seconds, and
•
then stops. Turn the ignition switch OFF. If the pump does not operate as described above, check the operating voltage (see Fuel Pump Operating Voltage Inspection).
FUEL SYSTEM (DFI) 3-93 Fuel Pump Fuel Pump Operating Voltage Inspection NOTE
○Be sure the battery is fully charged.
the ignition switch OFF. • Turn the fuel tank bolts (see Fuel Tank Removal). • Remove Disconnect the fuel pump lead connector and connect the • harness adapter [A] between these connectors as shown in the figure. Main Harness [B] Fuel Pump [C] Special Tool - Measuring Adapter: 57001-1700
• Connect a digital meter [D] to the harness adapter leads. Fuel Pump Operating Voltage Connections to Adapter: Digital Meter (+) → R (pump R) lead Digital Meter (–) → BK (pump BK) lead
the operating voltage with engine stopped and • Measure with the connector joined. the engine stop switch run position. • Turn • Turn the ignition switch ON. Operating Voltage Standard: Battery Voltage for 3 seconds, and then 0 V
the ignition switch OFF. • Turn If the reading stays on battery voltage and never shows 0 V, check the fuel pump relay (see Relay Circuit Inspection in the Electrical System chapter). If the pump relay is normal, check the ECU for its ground and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation). If there is still no battery voltage, check the ECU main relay and fuel pump relay (see Relay Circuit Inspection in the Electrical System chapter). If the main relay and pump relay are normal, check the wiring for continuity (see wiring diagram in this section). If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation). If the reading is in specification, but the pump does not operate, replace the fuel pump (see Fuel Pump Removal/Installation).
3-94 FUEL SYSTEM (DFI) Fuel Pump Pressure Regulator Removal
○The pressure regulator [A] is built into the fuel pump [B] and can not be removed.
Fuel Filter Cleaning
○The fuel filter [A] are built into the pump and can not be cleaned or checked. If the fuel filter is suspected of clogging or being damaged, replace it with the fuel pump as a set.
Fuel Pump Relay Removal/Installation
○The fuel pump relay is built in the relay box [A].
to the Relay Box Removal in the Electrical System • Refer chapter.
Fuel Pump Relay Inspection
to the Relay Circuit Inspection in the Electrical Sys• Refer tem chapter.
FUEL SYSTEM (DFI) 3-95 Fuel Pump Fuel Pump Circuit
1. Ignition Switch 2. Engine Stop Switch 3. Water-proof Joint 3 4. ECU 5. Joint Connector 2 6. Fuel Pump 7. Battery 12 V 8 Ah 8. Frame Ground 9. Main Fuse 30 A 10. Fuel Pump Relay 11. Relay Box 12. ECU Main Relay 13. Ignition Fuse 10 A 14. ECU Fuse 15 A 15. Fuse Box
3-96 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Removal/Installation
• Refer to the Throttle Body Assy Disassembly/Assembly. Fuel Injector Audible Inspection NOTE
○Be sure the battery is fully charged.
the lower fairings (see Lower Fairing Removal in • Remove the Frame chapter). the engine, and let it idle. • Start Apply of a screwdriver [A] to the fuel injector [B]. • Put thethegriptipend onto your ear, and listen whether the fuel injector is clicking or not. ○A sound scope can also be used. ○The click interval becomes shorter as the engine speed rises. Do the same for the other fuel injector. If all the fuel injectors click at a regular intervals, the fuel injectors are normal. Turn the ignition switch OFF. If any fuel injector does not click, check the fuel injector resistance (see Fuel Injector Resistance Inspection).
• •
Fuel Injector Resistance Inspection
the fuel tank (see Fuel Tank Removal). • Remove Disconnect the injector connector [A]. • Connect a digital to the terminals of the injector [B]. • Measure the fuel meter injector resistance. • Fuel Injector Resistance Connections: For Fuel Injector #1 W/R ←→ BL/R terminal For Fuel Injector #2 W/R ←→ BL/G terminal Standard: About 11.7 ∼ 12.3 Ω at 20°C (68°F)
If the reading is out of the standard, replace the injector. If the reading is within the standard, check the power source voltage (see Fuel Injector Power Source Voltage Inspection).
FUEL SYSTEM (DFI) 3-97 Fuel Injectors Fuel Injector Power Source Voltage Inspection NOTE
○Be sure the battery is fully charged.
the ignition switch OFF. • Turn the injector connector and connect the har• Disconnect ness adapter [A] between these connectors as shown in the figure. Main Harness [B] Fuel Injector #1 [C] Special Tool - Measuring Adapter: 57001-1700
• Connect a digital meter [D] to the harness adapter leads. Fuel Injector Power Source Voltage Connections to Adapter: For Fuel Injector #1, #2 Digital Meter (+) → R (injector W/R) lead Digital Meter (–) → Battery (–) terminal
the power source voltage with • Measure stopped. the engine stop switch to run position. • Turn Turn • the ignition switch ON.
the engine
Power Source Voltage Standard: Battery Voltage for 3 seconds, and then 0 V
the ignition switch OFF. • Turn If the reading stays on battery voltage and never shows 0 V, check the fuel pump relay (see Relay Circuit Inspection in the Electrical System chapter). If the pump relay is normal, check the ECU for its ground and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation). If there is still no battery voltage, check the ECU main relay and pump relay (see Relay Circuit Inspection in the Electrical System chapter). If the main relay and pump relay are normal, check the power source wiring (see wiring diagram in this section). If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation). If the reading is in specification, check the output voltage (see Fuel Injector Output Voltage Inspection).
3-98 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Output Voltage Inspection NOTE
○Be sure the battery is fully charged.
the ignition switch OFF. • Turn the ECU (see ECU Removal). •○Remove Do not disconnect the ECU connector. a digital meter [A] to the connector [B] with the • Connect needle adapter set. Special Tool - Needle Adapter Set: 57001-1457 Fuel Injector Output Voltage Connections to ECU Connector: For Fuel Injector #1 Digital Meter (+) → BL/R lead (ECU terminal 34) Digital Meter (–) → Battery (–) terminal For Fuel Injector #2 Digital Meter (+) → BL/G lead (ECU terminal 33) Digital Meter (–) → Battery (–) terminal
the output voltage with the engine stopped and • Measure with the connector joined. the engine stop switch to run position. • Turn Turn • the ignition switch ON. Output Voltage Standard: Battery Voltage for 3 seconds, and then 0 V
the ignition switch OFF. • Turn If the reading is in specification, check the ECU for its ground and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation). If the reading is out of the specification, remove the ECU and check the wiring for continuity between main harness connector. Special Tool - Hand Tster: 57001-1394
○Disconnect the ECU and injector connector. Wiring Continuity Inspection ECU Connector [A] ←→ Fuel Injector Connector [B] For Fuel Injector #1 [C] BL/R lead (ECU terminal 34) [D] For Fuel Injector #2 BL/G lead (ECU terminal 33)
If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection). If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).
FUEL SYSTEM (DFI) 3-99 Fuel Injectors Fuel Injector Fuel Line Inspection
• Remove: Fuel Tank (see Fuel Tank Removal)
Fuel Hose (see Fuel Hose Replacement in the Periodic Maintenance chapter) ○Be sure to place a piece of cloth around the fuel supply pipes of the fuel pump and the throttle body assy.
WARNING Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe because of residual pressure. Cover the hose connection with a piece of clean cloth to prevent fuel spillage. the injector fuel line for leakage as follows. •○Check Connect a commercially available vacuum/pressure
pump [A] to the nipple of the fuel supply pipe [B] with the fuel hose [C] (both ends with the clamps [D]) as shown in the figure. Right Side View [E] Apply soap and water solution to the areas [F] as shown ○ in the figure. ○Watching the pressure gauge, squeeze the pump lever [G], and build up the pressure until the pressure reaches the maximum pressure. Injector Fuel Line Maximum Pressure Standard: 300 kPa (3.06 kgf/cm², 43 psi)
CAUTION During pressure testing, do not exceed the maximum pressure for which the system is designed.
○Watch the gauge for at least 6 seconds.
If the pressure holds steady, the fuel line is good. If the pressure drops at once or if bubbles are found in the area, the fuel line is leaking. Replace the fuel supply pipe assy, injectors and related parts. ○Repeat the leak test, and check the fuel line for no leakage. Install: Fuel Hose (see Fuel Hose Replacement in the Periodic Maintenance chapter) Fuel Tank (see Fuel Tank Installation) Start the engine and check for fuel leakage.
• •
3-100 FUEL SYSTEM (DFI) Fuel Injectors Fuel Injector Circuit
1. Ignition Switch 2. Engine Stop Switch 3. Water-proof Joint 3 4. Fuel Injector #1, #2 5. ECU 6. Joint Connector 2 7. Fuel Pump 8. Battery 12 V 8 Ah 9. Frame Ground 10. Main Fuse 30 A 11. Fuel Pump Relay 12. Relay Box 13. ECU Main Relay 14. Ignition Fuse 10 A 15. ECU Fuse 15 A 16. Fuse Box
FUEL SYSTEM (DFI) 3-101 Throttle Grip and Cables Free Play Inspection
to the Throttle Control System Inspection in the Pe• Refer riodic Maintenance chapter.
Free Play Adjustment
to the Throttle Control System Inspection in the Pe• Refer riodic Maintenance chapter.
Cable Installation
the throttle cables in accordance with the Cable, • Install Wire, and Hose Routing section in the Appendix chapter. the lower ends of the throttle cables in the throttle • Install pulley on the throttle body assy after installing the upper
•
ends of the throttle cables in the grip. After installation, adjust each cable properly (see Throttle Control System Inspection in the Periodic Maintenance chapter).
WARNING Operation with incorrectly routed or improperly adjusted cables could result in an unsafe riding condition.
Cable Lubrication
to the Chassis Parts Lubrication in the Periodic • Refer Maintenance chapter.
3-102 FUEL SYSTEM (DFI) Throttle Body Assy Idle Speed Inspection/Adjustment
to the Idle Speed Inspection/Adjustment in the Pe• Refer riodic Maintenance chapter.
Synchronization Inspection/Adjustment
to the Engine Vacuum Synchronization Inspection • Refer in the Periodic Maintenance chapter.
Throttle Body Assy Removal
WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch OFF. Be prepared for fuel spillage: any spilled fuel must be completely wiped up immediately.
CAUTION Never drop the throttle body assy especially on a hard surface. Such a shock to the body assy can damage it.
• Remove: Fuel Tank (see Fuel Tank Removal) Vacuum Hose [A] Fuel Injector Connectors [B] Subthrottle Valve Actuator Connector [C]
• Disconnect: Main Throttle Sensor Connector [A] Subthrottle Sensor Connector [B]
FUEL SYSTEM (DFI) 3-103 Throttle Body Assy the nuts [A], and remove the throttle cable lower • Loosen ends [B].
• Remove: Bolts [A] Idle Adjusting Cable [B] (from Bracket)
• Remove: Air Switching Valve Hose [A] Bracket Bolts [B] Right Air Cleaner Housing Mounting Bolt [C]
the left air cleaner housing mounting bolt [A]. • Remove Loosen the clamp screws [B]. • Move [C] theairairduct cleaner [D] backward, and pull • out the air ducts from thehousing throttle body assy.
the throttle body assy holder clamp screws [A], • Loosen and pull out the throttle body assy [B] backward. the throttle body assy to left side of motorcycle. • Remove removing the throttle body assy, stuff pieces of lint• After free, clean cloth into the throttle body assy holders.
CAUTION If dirt gets into the engine, excessive engine wear and possible engine damage will occur.
3-104 FUEL SYSTEM (DFI) Throttle Body Assy Throttle Body Assy Installation
the throttle body assy holder clamp screws in the • Install direction as shown in the figure.
• •
Screw Heads [A] Install the throttle body assy to the throttle body assy holders. Tighten: Torque - Throttle Body Assy Holder Clamp Screws: 2.0 N·m (0.20 kgf·m, 18 in·lb)
the air duct clamp screws in the direction as shown • Install in the figure.
• •
Screw Heads [A] About 21° [B] Install the air ducts to the throttle body assy. Tighten: Torque - Air Duct Clamp Screws: 2.0 N·m (0.20 kgf·m, 18 in·lb) Air Cleaner Housing Mounting Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
a thin coating of grease to the throttle cable lower • Apply ends. the accelerator cable end and the decelerator cable • Fit end into the throttle pulley. the throttle grip and make sure that the throttle valves • Turn move smoothly and return by spring force. the leads and hoses correctly (see Cable, Wire, and • Run Hose Routing section in the Appendix chapter). • Adjust: Throttle Grip Free Play (see Throttle Control System Inspection in the Periodic Maintenance chapter) Idle Speed (see Idle Speed Adjustment in the Periodic Maintenance chapter)
FUEL SYSTEM (DFI) 3-105 Throttle Body Assy Throttle Body Assy Disassembly
1. Subthrottle Valve Actuator 2. Subthrottle Sensor 3. Main Throttle Sensor 4. Throttle Body Assy 5. Fuel Injectors 6. Delivery Pipe Assy
CAUTION Do not remove, disassemble or adjust the main throttle sensor, subthrottle sensor, subthrottle valve actuator, throttle link mechanism and throttle body assy, because they are adjust or set surely at the manufacturer. Adjustment of these parts could result in poor performance, requiring replacement of the throttle body assy. the throttle body assy (see Throttle Body Assy • Remove Removal). the band [A]. • Cut Remove the screws [B] to pull out the injectors from the • throttle body assy together with the delivery pipe assy [C].
NOTE
○Do not damage the insertion portions of the injectors when they are pulled out from the throttle body.
3-106 FUEL SYSTEM (DFI) Throttle Body Assy
• Pull out the injectors [A] from the delivery pipe assy [B]. NOTE
○Do not damage the insertion portions of the injectors when they are pulled out from the delivery pipe assy.
CAUTION Never drop the fuel injector especially on a hard surface. Such a shock to the injector can damage it.
Throttle Body Assy Assembly
assembling, blow away dirt or dust from the throttle • Before body and delivery pipe by applying compressed air. the O-rings [A] of each injector [B] with new ones. • Replace engine oil to the new O-rings, insert them to the • Apply delivery pipe assy [C] and confirm whether the injectors turn smoothly or not.
the dust seals [A] with new ones. • Replace Apply engine oil to the new dust seals. • Install the injectors • the throttle body. along with the delivery pipe assy to • Tighten: Torque - Delivery Pipe Assy Mounting Screws: 3.4 N·m (0.35 kgf·m, 30 in·lb)
the lead with band. • Bind Install the throttle body assy (see Throttle Body Assy In• stallation).
FUEL SYSTEM (DFI) 3-107 Air Cleaner Air Cleaner Element Removal/Installation
to the Air Cleaner Element Replacement in the Pe• Refer riodic Maintenance chapter.
Air Cleaner Element Inspection
the air cleaner element (see Air Cleaner Element • Remove Replacement in the Periodic Maintenance chapter). check the element [A] for tears or breaks. • Visually If the element has any tears or breaks, replace the element.
Air Cleaner Oil Draining
check the drain cap [A] if the water or oil accu• Visually mulates. If any water or oil accumulates in the cap, remove the cap and drain it.
WARNING Be sure to reinstall the cap after draining. Oil on tires will make them slippery and can cause an accident and injury.
Air Cleaner Housing Removal
• Remove: Rear Wheel
(see Rear Wheel Removal in the Wheels/Tires chapter) Fuel Tank (see Fuel Tank Removal) Air Switching Valve Hose [A] Bracket Bolts [B] Right Air Cleaner Housing Mounting Bolt [C] Rear Fender (see Flap and Rear Fender Removal in the Frame chapter)
• Remove: Left Air Cleaner Housing Mounting Bolt [A] Breather Hose [B]
3-108 FUEL SYSTEM (DFI) Air Cleaner the air duct clamp screws [A]. • Loosen Remove air cleaner housing [B], pulling out the duct • portion [C]thefrom the grommet.
removing the air cleaner housing, stuff pieces of lint• After free, clean cloth into the throttle body assy.
CAUTION If dirt gets into the engine, excessive engine wear and possible engine damage will occur.
Air Cleaner Housing Installation
is the reverse of removal. •○Install Install the air duct clamp screws in the direction as shown in the figure. Screw Heads [A] About 21° [B]
○Insert the duct portion [A] into the grommet [B]. ○Tighten: Torque - Air Duct Clamp Screws: 2.0 N·m (0.20 kgf·m, 18 in·lb) Air Cleaner Housing Mounting Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
• Install the removed parts (see appropriate chapters). Air Cleaner Housing Disassembly
• Remove: Air Cleaner Housing (see Air Cleaner Housing Removal) Air Cleaner Element (see Air Cleaner Element Replacement in the Periodic Maintenance chapter) Screws [A] Right Cover [B] Flame Arrester
FUEL SYSTEM (DFI) 3-109 Air Cleaner Air Cleaner Housing Assembly
the flame arrester [A]. • Install Be sure the O-ring [B] is in position. •
a adhesive cement to the slash portion [A] of the air • Apply cleaner housing. the right cover. • Install Tighten: • Torque - Air Cleaner Housing Screws: kgf·m, 10 in·lb)
1.15 N·m (0.12
3-110 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank Removal
WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch OFF and disconnect the battery (–) terminal. To avoid fire, do not remove the fuel tank when the engine is still hot. Wait until it cools down. To make fuel spillage minimum, draw the fuel out from the fuel tank when the engine is cold. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. the ignition switch OFF. • Turn Wait until cools down. • Disconnectthetheengine battery terminal (see Battery Removal • in the Electrical System(–)chapter). • Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Front Seat (see Front Seat Removal in the Frame chapter) Fuel Tank Bolts [A]
• Pull off the fuel tank drain hose [A] from the fuel tank.
the fuel tank cap [A] to lower the pressure in the • Open tank.
FUEL SYSTEM (DFI) 3-111 Fuel Tank the fuel out from the fuel tank with a commercially • Draw available pump [A].
○Use a soft plastic hose [B] as a pump inlet hose in order to insert the hose smoothly.
○Put the hose through the fill opening [C] into the tank and draw the fuel out. Front [D]
WARNING The fuel could not be removed completely from the fuel tank. Be careful for remained fuel spillage.
• Disconnect the fuel pump lead connector [A].
sure to place a piece of cloth [A] around the fuel hose • Be joint [B]. • Push the joint lock claws [C].
the joint lock [A] as shown in the figure. • Pull Pull [B] the fuel hose joint [C] out of the fuel supply pipe. •
WARNING
Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately. When the fuel hose is disconnected, fuel spills out from the hose and the pipe because of residual pressure. Cover the hose connection with a piece of clean cloth to prevent fuel spillage. the fuel tank cap. • Close Remove the fuel tank, and place a it on a flat surface. •
3-112 FUEL SYSTEM (DFI) Fuel Tank Fuel Tank Installation
the above WARNING (see Fuel Tank Removal). • Note Run the hoses correctly (see Cable, Wire, and Hose Rout• ing section in the Appendix chapter). Check that the • the fuel tank. dampers [A] are in place on the frame and If the dampers are damaged or deteriorated, replace them.
• Pull the joint lock [A] as shown in the figure.
the fuel hose joint [A] straight onto the fuel supply • Insert pipe until the hose joint clicks. • Push the joint lock [B] until the hose joint clicks.
and pull [A] the hose joint [B] back and forth more • Push than two times, and make sure it is locked and does not come off.
WARNING Make sure the hose joint is installed correctly on the supply pipe or the fuel could leak.
•
If it comes off, reinstall the hose joint. Connect the fuel pump lead connector and the battery (–) terminal (see Battery Installation in the Electrical System chapter).
FUEL SYSTEM (DFI) 3-113 Fuel Tank Fuel Tank Inspection
the tank cap. • Open Visually • damage.inspect the gasket [A] on the tank cap for any
•
Replace the gasket if it is damaged. Check to see if the water drain pipe [B] in the tank are not clogged. Check the tank cap breather also. If they are clogged, remove the tank and drain it, and then blow the breather free with compressed air.
CAUTION Do not apply compressed air to the air vent holes [C] in the tank cap. This could cause damage and clogging of the labyrinth in the cap.
Fuel Tank Cleaning
WARNING Clean the tank in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area. Because of the danger or highly flammable liquids, do not use gasoline or low-flash point solvents to clean the tank.
• Remove: Fuel Tank (see Fuel Tank Removal) • • • •
Fuel Pump (see Fuel Pump Removal) Pour some high-flash point solvent into the fuel tank and shake the tank to remove dirt and fuel deposits. Draw the solvent out of the fuel tank. Dry the tank with compressed air. Install: Fuel Pump (see Fuel Pump Installation) Fuel Tank (see Fuel Tank Installation)
COOLING SYSTEM 4-1
Cooling System Table of Contents Exploded View........................................................................................................................ Coolant Flow Chart................................................................................................................. Specifications ......................................................................................................................... Coolant ................................................................................................................................... Coolant Deterioration Inspection....................................................................................... Coolant Level Inspection................................................................................................... Coolant Draining ............................................................................................................... Coolant Filling ................................................................................................................... Pressure Testing ............................................................................................................... Cooling System Flushing .................................................................................................. Coolant Reserve Tank Removal ....................................................................................... Coolant Reserve Tank Installation .................................................................................... Water Pump............................................................................................................................ Water Pump Cover Removal ............................................................................................ Water Pump Cover Installation ......................................................................................... Water Pump Removal ....................................................................................................... Water Pump Installation .................................................................................................... Water Pump Impeller Inspection ....................................................................................... Radiator .................................................................................................................................. Radiator and Radiator Fan Removal ................................................................................ Radiator and Radiator Fan Installation ............................................................................. Radiator Inspection ........................................................................................................... Radiator Cap Inspection ................................................................................................... Radiator Filler Neck Inspection ......................................................................................... Thermostat ............................................................................................................................. Thermostat Removal......................................................................................................... Thermostat Installation...................................................................................................... Thermostat Housing Removal .......................................................................................... Thermostat Housing Installation ....................................................................................... Thermostat Inspection ...................................................................................................... Hoses and Pipes .................................................................................................................... Hose Installation ............................................................................................................... Hose Inspection ................................................................................................................ Water Temperature Sensor .................................................................................................... Water Temperature Sensor Removal/Installation ............................................................. Water Temperature Sensor Inspection .............................................................................
4-2 4-4 4-6 4-7 4-7 4-7 4-7 4-7 4-7 4-8 4-8 4-8 4-9 4-9 4-9 4-9 4-9 4-10 4-11 4-11 4-12 4-12 4-12 4-13 4-14 4-14 4-14 4-14 4-14 4-15 4-16 4-16 4-16 4-17 4-17 4-17
4
4-2 COOLING SYSTEM Exploded View
COOLING SYSTEM 4-3 Exploded View No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Fastener Coolant Drain Bolt (Cylinder) Coolant Drain Bolt (Water Pump) Radiator Bolts Radiator Cap Bracket Bolt Radiator (Water) Hose Clamp Screws Reserve Tank Bolts Reserve Tank Bracket Bolts Reserve Tank Cap Resistor Bolt Thermostat Cover Bolts Thermostat Housing Mounting Bolts Water Hose Fitting Bolts Water Pipe Bolts Water Pump Bolts Water Pump Cover Bolts Water Temperature Sensor
G: Apply grease. R: Replacement Parts
N·m 5.9 9.8 9.8 9.8 1.5 9.8 9.8 – 7.8 9.8 9.8 9.8 9.8 9.8 9.8 25
Torque kgf·m 0.60 1.0 1.0 1.0 0.15 1.0 1.0 – 0.80 1.0 1.0 1.0 1.0 1.0 1.0 2.5
ft·lb 52 in·lb 87 in·lb 87 in·lb 87 in·lb 13 in·lb 87 in·lb 87 in·lb – 69 in·lb 87 in·lb 87 in·lb 87 in·lb 87 in·lb 87 in·lb 87 in·lb 18
Remarks
Hand-Tighten
4-4 COOLING SYSTEM Coolant Flow Chart
COOLING SYSTEM 4-5 Coolant Flow Chart Permanent type antifreeze is used as a coolant to protect the cooling system from rust and corrosion. When the engine starts, the water pump turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes with coolant temperature changes. The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level. When coolant temperature is less than 63.5 ∼ 66.5°C (146 ∼ 152°F), the thermostat closes so that the coolant flow is restricted through the air bleeder hole, causing the engine to warm up more quickly. When coolant temperature is more than 63.5 ∼ 66.5°C (146 ∼ 152°F), the thermostat opens and the coolant flows. When the coolant temperature goes up beyond 103°C (217°F), the radiator fan relay conducts to operate the radiator fan. The radiator fan draws air through the radiator core when there is not sufficient air flow such as at low speeds. This increases up the cooling action of the radiator. When the coolant temperature is below 98°C (208°F), the fan relay opens and the radiator fan stops. In this way, this system controls the engine temperature within narrow limits where the engine operates most efficiently even if the engine load varies. The system is pressurized by the radiator cap to suppress boiling and the resultant air bubbles which can cause engine overheating. As the engine warms up, the coolant in the radiator and the water jacket expands. The excess coolant flows through the radiator cap and hose to the reserve tank to be stored there temporarily. Conversely, as the engine cools down, the coolant in the radiator and the water jacket contracts, and the stored coolant flows back to the radiator from the reserve tank. The radiator cap has two valves. One is a pressure valve which holds the pressure in the system when the engine is running. When the pressure exceeds 93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 13 ∼ 18 psi), the pressure valve opens and releases the pressure to the reserve tank. As soon as pressure escapes, the valve closes, and keeps the pressure at 93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 13 ∼ 18 psi). When the engine cools down, another small valve (vacuum valve) in the cap opens. As the coolant cools, the coolant contracts to form a vacuum in the system. The vacuum valve opens and allows the coolant from the reserve tank to enter the radiator.
4-6 COOLING SYSTEM Specifications Item Coolant Provided when Shipping Type (Recommended)
Color Mixed Ratio Freezing Point Total Amount Radiator Cap Relief Pressure Thermostat Valve Opening Temperature Valve Full Opening Lift
Standard Permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Green Soft water 50%, coolant 50% −35°C (−31°F) 1.5 L (1.6 US qt) (reserve tank full level, including radiator and engine) 93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 13 ∼ 18 psi) 63.5 ∼ 66.5°C (146 ∼ 152°F) 6 mm (0.24 in.) or more at 80°C (176°F)
COOLING SYSTEM 4-7 Coolant Coolant Deterioration Inspection
the right lower fairing (see Lower Fairing Re• Remove moval in the Frame chapter). inspect the coolant [A] in the reserve tank. • Visually If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case, flush the cooling system. If the coolant gives off an abnormal smell, check for a cooling system leak. It may be caused by exhaust gas leaking into the cooling system.
Coolant Level Inspection
to the Coolant Level Inspection in the Periodic Main• Refer tenance chapter.
Coolant Draining
to the Coolant Change in the Periodic Maintenance • Refer chapter.
Coolant Filling
to the Coolant Change in the Periodic Maintenance • Refer chapter.
Pressure Testing
the right lower fairing (see Lower Fairing Re• Remove moval in the Frame chapter). the radiator cap, and install a cooling system • Remove pressure tester [A] on the filler neck.
NOTE
○Wet the cap sealing surfaces with water or coolant to prevent pressure leaks.
up pressure in the system carefully until the pres• Build sure reaches 123 kPa (1.25 kgf/cm², 18 psi).
CAUTION During pressure testing, do not exceed the pressure for which the system is designed. The maximum pressure is 123 kPa (1.25 kgf/cm², 18 psi). the gauge for at least 6 seconds. • Watch If the pressure holds steady, the system is all right.
•
If the pressure drops and no external source is found, check for internal leaks. Droplets in the engine oil indicate internal leakage. Check the cylinder head gasket and the water pump. Remove the pressure tester, replenish the coolant, and install the radiator cap.
4-8 COOLING SYSTEM Coolant Cooling System Flushing Over a period of time, the cooling system accumulates rust, scale, and lime in the water jacket and radiator. When this accumulation is suspected or observed, flush the cooling system. If this accumulation is not removed, it will clog up the water passage and considerable reduce the efficiency of the cooling system. Drain the cooling system (see Coolant Change in the Periodic Maintenance chapter). Fill the cooling system with fresh water mixed with a flushing compound.
• •
CAUTION Do not use a flushing compound which is harmful to the aluminum engine and radiator. Carefully follow the instructions supplied by the manufacturer of the cleaning product. up the engine, and run it at normal operating tem• Warm perature for about ten minutes. the engine, and drain the cooling system. • Stop Fill the with fresh water. • Warm upsystem the engine and drain the system. • Repeat the previous two steps once more. • Fill the system with a permanent type coolant and bleed • the air from the system (see Coolant Change in the Periodic Maintenance chapter).
Coolant Reserve Tank Removal
• Remove: Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Coolant [A] (from Reserve Tank) (Drain, see Coolant Change in the Periodic Maintenance chapter) Bolts [B] Hoses [C] Clutch Cable [D] (see Clutch Cable Removal in the Clutch chapter) Coolant Reserve Tank [E]
Coolant Reserve Tank Installation
is the reverse of removal. • Installation Run the cable and hoses correctly (see Cable, Wire, and • Hose Routing section in the Appendix chapter). Install the removed parts (see appropriate chapters). • Torque - Reserve Tank Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
COOLING SYSTEM 4-9 Water Pump Water Pump Cover Removal
• Remove: Coolant (Drain,
see Coolant Change in the Periodic Maintenance chapter) Left Lower Fairing (see Lower Fairing Removal in the Frame chapter) Engine Sprocket Cover (see Engine Sprocket Removal in the Final Drive chapter) Bolts [A] and Water Pipes [B]
• Remove: Water Pump Cover Bolts [A] Water Pump Cover [B]
Water Pump Cover Installation
grease to a new O-ring [A]. • Apply Fit the O-ring into the groove of the water pump cover [B]. • Install the • the bolts. water pump cover and water pipes, and tighten Torque - Water Pump Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) Water Pipe Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
• Install the removed parts (see appropriate chapters). Water Pump Removal
• Remove: Water Pump Cover (see Water Pump Cover Removal) Water Pump Bolts [A] Water Pump [B]
Water Pump Installation
grease to a new O-ring [A]. • Apply Install the water pump aligning the slot [B] of the water • pump shaft with the oil pump shaft. Tighten: • Torque - Water Pump Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
4-10 COOLING SYSTEM Water Pump Water Pump Impeller Inspection
the water pump (see Water Pump Removal). • Remove Visually inspect impeller [A]. • If the surface is the corroded or if the blades are damaged, replace the water pump unit.
COOLING SYSTEM 4-11 Radiator Radiator and Radiator Fan Removal
WARNING The radiator fan is connected directly to the battery. The radiator fan may start even if the ignition switch is off. NEVER TOUCH THE RADIATOR FAN UNTIL THE RADIATOR FAN MOTOR LEAD CONNECTOR IS DISCONNECTED. TOUCHING THE FAN BEFORE THE CONNECTOR IS DISCONNECTED COULD CAUSE INJURY FROM THE FAN BLADES.
• Remove: Inner Fairing (see Inner Fairing Removal in the Frame chapter) Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter) Resistor (see Resistor Inspection in the Electrical System chapter) Radiator Hose Clamp Screw [A] (Loosen) Radiator Bolts [B]
• Remove: Radiator Hose Clamp Screw [A] (Loosen) Radiator Bolts [B]
• Remove: Radiator Fan Motor Lead Connector [A] (Disconnect) Radiator [B]
CAUTION Do not touch the radiator core. This could damage the radiator fins, resulting in loss of cooling efficiency.
• Remove: Radiator Fan Mounting Bolts [A] Radiator Fan [B]
4-12 COOLING SYSTEM Radiator Radiator and Radiator Fan Installation
is the reverse of removal. • Installation Run the leads correctly (see Cable, Wire, and Hose Rout• ing section in the Appendix chapter). Cover the heat insulation rubber plate on the radiator • (see Engine Installation in the Engine Removal/Installa-
•
tion chapter). Install the removed parts (see appropriate chapters). Torque - Radiator Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) Radiator (Water) Hose Clamp Screws: 1.5 N·m (0.15 kgf·m, 13 in·lb) Resistor Bolt: 7.8 N·m (0.80 kgf·m, 69 in·lb)
Radiator Inspection
the radiator core. • Check If there are obstructions to air flow, remove them. If the corrugated fins [A] are deformed, carefully straighten them. If the air passages of the radiator core are blocked more than 20% by unremovable obstructions or irreparably deformed fins, replace the radiator with a new one.
CAUTION When cleaning the radiator with steam cleaner, be careful of the following to prevent radiator damage: Keep the steam gun [A] away more than 0.5 m (1.6 ft) [B] from the radiator core. Hold the steam gun perpendicular [C] (not oblique [D]) to the core surface. Run the steam gun, following the core fin direction.
Radiator Cap Inspection
• Remove: Right Lower Fairing (see Lower Fairing Removal in the •
Frame chapter) Radiator Cap Check the condition of the bottom [A] and top [B] valve seals and valve spring [C]. If any one of them shows visible damage, replace the cap with a new one.
COOLING SYSTEM 4-13 Radiator
• Install the cap [A] on a cooling system pressure tester [B]. NOTE
○Wet the cap sealing surfaces with water or coolant to prevent pressure leaks.
the pressure gauge, pump the pressure tester • Watching to build up the pressure until the relief valve opens: the gauge needle flicks downward. Stop pumping and measure leak time at once. The relief valve must open within the specified range in the table below and the gauge hand must remain within the same range at least 6 seconds. Radiator Cap Relief Pressure Standard: 93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 13 ∼ 18 psi)
If the cap can not hold the specified pressure or if it holds too much pressure, replace it with a new one.
Radiator Filler Neck Inspection
• Remove: Right Lower Fairing (see Lower Fairing Removal in the • •
Frame chapter) Radiator Cap Check the radiator filler neck for signs of damage. Check the condition of the top and bottom sealing seats [A] in the filler neck. They must be smooth and clean for the radiator cap to function properly.
4-14 COOLING SYSTEM Thermostat Thermostat Removal
• Remove: Coolant (Drain,
see Coolant Change in the Periodic Maintenance chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Thermostat Cover Bolts [A]
the thermostat cover [A] outwards and remove the • Move thermostat [B].
Thermostat Installation
the thermostat [A] in the housing so that the air • Install bleeder hole [B] as shown in the figure. • Tighten: Torque - Thermostat Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
• Install the removed parts (see appropriate chapters). Thermostat Housing Removal
• Remove: Coolant (Drain,
see Coolant Change in the Periodic Maintenance chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Water Temperature Sensor Connector [A] (Disconnect) Hose Clamp Screws [B] (Loosen) Hoses [C] Bolts [D] Thermostat Housing [E]
Thermostat Housing Installation
sure to install the ground lead on the thermostat hous• Be ing mounting bolt. • Tighten:
Torque - Thermostat Housing Mounting Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) Radiator (Water) Hose Clamp Screws: 1.5 N·m (0.15 kgf·m, 13 in·lb)
• Install the removed parts (see appropriate chapters).
COOLING SYSTEM 4-15 Thermostat Thermostat Inspection
the thermostat (see Thermostat Removal), and • Remove inspect the thermostat valve [A] at room temperature. If the valve is open, replace the thermostat with a new one.
check valve opening temperature, suspend the ther• To mostat [A] in a container of water and raise the temperature of the water. ○The thermostat must be completely submerged and must not touch the container sides or bottom. Suspend an accurate thermometer [B] in the water so that the heat sensitive portions [C] are located in almost the same depth. It must not touch the container, either. If the measurement is out of the specified range, replace the thermostat with a new one. Thermostat Valve Opening Temperature 63.5 ∼ 66.5°C (146 ∼ 152°F)
4-16 COOLING SYSTEM Hoses and Pipes Hose Installation
the hoses and pipes, being careful to follow bend• Install ing direction. Avoid sharp bending, kinking, flattening or twisting. Run the hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). Install the clamp [A] as near as possible to the hose end to clear the raised rib of the fitting. This will prevent the hoses from working loose. ○The clamp screws should be positioned correctly to prevent the clamps from contacting the other parts.
• •
Torque - Radiator (Water) Hose Clamp Screws: 1.5 N·m (0.15 kgf·m, 13 in·lb)
Hose Inspection
to the Water Hose and Pipe Inspection in the Peri• Refer odic Maintenance chapter.
COOLING SYSTEM 4-17 Water Temperature Sensor CAUTION The water temperature sensor should never be allowed to fall on a hard surface. Such a shock to the water temperature sensor can damage it.
Water Temperature Sensor Removal/Installation
to the Water Temperature Sensor Removal/Instal• Refer lation in the Fuel System (DFI) chapter.
Water Temperature Sensor Inspection
to the Water Temperature Sensor Inspection in the • Refer Electrical System chapter.
ENGINE TOP END 5-1
Engine Top End Table of Contents Exploded View................................... Exhaust System................................. Specifications .................................... Special Tools and Sealant ................. Clean Air System............................... Air Suction Valve Removal........... Air Suction Valve Installation........ Air Suction Valve Inspection ........ Air Switching Valve Removal ....... Air Switching Valve Installation .... Air Switching Valve Operation Test............................................ Air Switching Valve Unit Test ....... Clean Air System Hose Inspection.................................. Cylinder Head Cover ......................... Cylinder Head Cover Removal .... Cylinder Head Cover Installation . Camshaft Chain Tensioner ................ Camshaft Chain Tensioner Removal .................................... Camshaft Chain Tensioner Installation ................................. Camshaft, Camshaft Chain ............... Camshaft Removal ...................... Camshaft Installation ................... Camshaft, Camshaft Cap Wear Inspection.................................. Camshaft Runout Inspection........ Cam Wear Inspection .................. Camshaft Chain Removal ............ Cylinder Head.................................... Cylinder Compression Measurement ............................ Cylinder Head Removal ............... Cylinder Head Installation ............
5-2 5-6 5-7 5-9 5-11 5-11 5-11 5-11 5-12 5-12 5-12 5-12 5-12 5-13 5-13 5-13 5-15 5-15 5-15 5-17 5-17 5-18 5-20 5-20 5-21 5-21 5-22 5-22 5-23 5-24
Cylinder Head Warp Inspection ... Valves ................................................ Valve Clearance Inspection ......... Valve Clearance Adjustment ....... Valve Removal ............................. Valve Installation .......................... Valve Guide Removal .................. Valve Guide Installation ............... Valve-to-Guide Clearance Measurement (Wobble Method) ..................................... Valve Seat Inspection .................. Valve Seat Repair ........................ Cylinder, Pistons................................ Cylinder Removal......................... Cylinder Installation...................... Piston Removal............................ Piston Installation......................... Cylinder Wear Inspection............. Piston Wear Inspection ................ Piston Ring, Piston Ring Groove Wear Inspection ........................ Piston Ring Groove Width Inspection.................................. Piston Ring Thickness Inspection Piston Ring End Gap Inspection .. Boring, Honing Performance ....... Throttle Body Assy Holder................. Throttle Body Assy Holder Installation ................................. Muffler................................................ Muffler Body Removal.................. Muffler Body Installation............... Exhaust Pipe Removal................. Exhaust Pipe Installation..............
5-25 5-26 5-26 5-26 5-26 5-26 5-26 5-27 5-27 5-28 5-28 5-33 5-33 5-33 5-33 5-34 5-35 5-35 5-36 5-36 5-36 5-37 5-37 5-38 5-38 5-39 5-39 5-39 5-40 5-41
5
5-2 ENGINE TOP END Exploded View
ENGINE TOP END 5-3 Exploded View No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Fastener Air Suction Valve Cover Bolts Air Switching Valve Bracket Bolts Camshaft Cap Bolts Camshaft Chain Tensioner Cap Bolt Camshaft Chain Tensioner Mounting Bolts Camshaft Sprocket Bolts Coolant Drain Bolt (Cylinder) Cylinder Head Bolts (M8) Cylinder Head Bolt (M6) Cylinder Head Cover Bolts Cylinder Head Jacket Plugs Rear Camshaft Chain Guide Bolt Spark Plugs Throttle Body Assy Holder Clamp Screws
N·m 9.8 9.8 12 5.0 9.8 15 5.9 31.4 12 9.8 20 17 13 2.0
Torque kgf·m 1.0 1.0 1.2 0.51 1.0 1.5 0.60 3.2 1.2 1.0 2.0 1.7 1.3 0.20
ft·lb 87 in·lb 87 in·lb 106 in·lb 44 in·lb 87 in·lb 11 52 in·lb 23.2 106 in·lb 87 in·lb 15 13 115 in·lb 18 in·lb
EO: Apply engine oil. L: Apply a non-permanent locking agent. M: Apply molybdenum disulfide grease. MO: Apply molybdenum disulfide oil solution. (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1) R: Replacement Parts S: Follow the specified tightening sequence. SS: Apply silicone sealant.
Remarks
S
L MO, S S L
5-4 ENGINE TOP END Exploded View
ENGINE TOP END 5-5 Exploded View No. 1 2 3 4 5 6 7 8
Fastener Exhaust Pipe Holder Nuts Exhaust Pipe Mounting Bolt Muffler Body Clamp Bolt Muffler Body Mounting Bolt Muffler Body Rear Cover Bolts Muffler Cover Bolts Muffler Cover Clamp Bolt Muffler Cover Clamp Screw
L: Apply a non-permanent locking agent. R: Replacement Parts
N·m 12 9.8 17 30 9.8 9.8 9.8 6.9
Torque kgf·m 1.2 1.0 1.7 3.1 1.0 1.0 1.0 0.70
ft·lb 106 in·lb 87 in·lb 13 22 87 in·lb 87 in·lb 87 in·lb 61 in·lb
Remarks
L
5-6 ENGINE TOP END Exhaust System Exhaust System
Manifold Mark Position [A]
Muffler Body Mark Position [B]
Honeycomb Type Catalyst Position [D]
Manifold with Hole [E] for Oxygen Sensor [F].
Honeycomb Type Catalyst Position [C]
ENGINE TOP END 5-7 Specifications Item Camshafts Cam Height: Exhaust Inlet Camshaft Journal, Camshaft Cap Clearance Camshaft Journal Diameter Camshaft Bearing Inside Diameter Camshaft Runout Cylinder Head Cylinder Compression
Cylinder Head Warp Valves Valve Clearance: Exhaust Inlet Valve Head Thickness: Exhaust Inlet Valve Stem Bend Valve Stem Diameter: Exhaust Inlet Valve Guide Inside Diameter: Exhaust Inlet Valve/Valve Guide Clearance (Wobble Method): Exhaust Inlet Valve Seat Cutting Angle Valve Seating Surface: Width: Exhaust Inlet Outside Diameter: Exhaust Inlet Valve Spring Free Length: Exhaust Inlet
Standard
Service Limit
32.843 ∼ 32.957 mm (1.2930 ∼ 1.2975 in.) 33.843 ∼ 33.957 mm (1.3324 ∼ 1.3369 in.) 0.028 ∼ 0.071 mm (0.0011 ∼ 0.0028 in.)
32.74 mm (1.289 in.) 33.74 mm (1.328 in.) 0.16 mm (0.0063 in.)
23.950 ∼ 23.972 mm (0.9429 ∼ 0.9438 in.) 24.000 ∼ 24.021 mm (0.9449 ∼ 0.9457 in.)
23.92 mm (0.942 in.) 24.08 mm (0.948 in.)
TIR 0.02 mm (0.0008 in.) or less (Usable Range) 1 050 ∼ 1 500 kPa (10.7 ∼ 15.3 kgf/cm², 152 ∼ 218 psi) at 500 r/min (rpm) –––
0.22 ∼ 0.29 mm (0.0087 ∼ 0.0114 in.) 0.15 ∼ 0.24 mm (0.0059 ∼ 0.0094 in.) 0.8 mm (0.032 in.) 0.5 mm (0.020 in.) TIR 0.01 mm (0.0004 in.) or less
TIR 0.1 mm (0.004 in.)
– – – 0.05 mm (0.002 in.)
– – – – – – 0.5 mm (0.020 in.) 0.3 mm (0.012 in.) TIR 0.05 mm (0.002 in.)
4.455 ∼ 4.470 mm (0.1754 ∼ 0.1760 in.) 4.475 ∼ 4.490 mm (0.1762 ∼ 0.1768 in.)
4.44 mm (0.175 in.) 4.46 mm (0.176 in.)
4.500 ∼ 4.512 mm (0.1772 ∼ 0.1776 in.) 4.500 ∼ 4.512 mm (0.1772 ∼ 0.1776 in.)
4.58 mm (0.180 in.) 4.58 mm (0.180 in.)
0.07 ∼ 0.12 mm (0.0028 ∼ 0.0047 in.) 0.02 ∼ 0.08 mm (0.0008 ∼ 0.0032 in.) 32°, 45°, 67.5°
0.27 mm (0.011 in.) 0.23 mm (0.010 in.) – – –
0.5 ∼ 1.0 mm (0.0197 ∼ 0.0394 in.) 0.5 ∼ 1.0 mm (0.0197 ∼ 0.0394 in.)
– – – – – –
19.3 ∼ 19.5 mm (0.7598 ∼ 0.7677 in.) 21.9 ∼ 22.1 mm (0.8622 ∼ 0.8701 in.)
– – – – – –
39.5 mm (1.555 in.) 39.5 mm (1.555 in.)
38.0 mm (1.50 in.) 38.0 mm (1.50 in.)
5-8 ENGINE TOP END Specifications Item Cylinder, Pistons Cylinder Inside Diameter Piston Diameter Piston/Cylinder Clearance Oversize Pistons and Rings Piston Ring/Groove Clearance: Top Second Piston Ring Groove Width: Top Second Piston Ring Thickness: Top Second Piston Ring End Gap: Top Second Oil
Standard
Service Limit
62.000 ∼ 62.012 mm (2.4409 ∼ 2.4414 in.) 62.10 mm (2.4449 in.) 61.942 ∼ 61.957 mm (2.4387 ∼ 2.4392 in.) 61.79 mm (2.4327 in.) 0.043 ∼ 0.070 mm (0.0017 ∼ 0.0028 in.) – – – +0.5 mm (0.020 in.) – – –
0.03 ∼ 0.07 mm (0.0012 ∼ 0.0028 in.) 0.02 ∼ 0.06 mm (0.0008 ∼ 0.0024 in.)
0.17 mm (0.0067 in.) 0.16 mm (0.0063 in.)
0.82 ∼ 0.84 mm (0.0323 ∼ 0.0331 in.) 0.81 ∼ 0.83 mm (0.0319 ∼ 0.0327 in.)
0.92 mm (0.0362 in.) 0.91 mm (0.0358 in.)
0.77 ∼ 0.79 mm (0.0303 ∼ 0.0311 in.) 0.77 ∼ 0.79 mm (0.0303 ∼ 0.0311 in.)
0.70 mm (0.028 in.) 0.70 mm (0.028 in.)
0.15 ∼ 0.30 mm (0.0059 ∼ 0.0118 in.) 0.40 ∼ 0.55 mm (0.0157 ∼ 0.0217 in.) 0.20 ∼ 0.80 mm (0.0079 ∼ 0.0315 in.)
0.6 mm (0.024 in.) 0.9 mm (0.035 in.) 1.1 mm (0.043 in.)
ENGINE TOP END 5-9 Special Tools and Sealant Compression Gauge, 20 kgf/cm²: 57001-221
Valve Seat Cutter Holder Bar: 57001-1128
Valve Spring Compressor Assembly: 57001-241
Valve Seat Cutter, 32° 57001-1206
Piston Pin Puller Assembly: 57001-910
Valve Seat Cutter, 67.5° 57001-1207
Valve Seat Cutter, 45° 57001-1113
24.5:
Valve Spring Compressor Adapter, 57001-1305
Valve Seat Cutter, 32° 57001-1118
25:
Compression Gauge Adapter, M10 × 1.0: 57001-1317
22:
22:
16:
5-10 ENGINE TOP END Special Tools and Sealant Valve Seat Cutter Holder, 57001-1330
Valve Guide Arbor, 57001-1331
Valve Guide Reamer, 57001-1333
Piston Base, 57001-1336
2.3:
4.5:
4.5:
4.5:
Valve Guide Driver: 57001-1564
Washer: 57001-1720
Kawasaki Bond (Silicone Sealant): 92104-0004
ENGINE TOP END 5-11 Clean Air System Air Suction Valve Removal
• Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System •
(DFI) chapter) Air Switching Valve (see Air Switching Valve Removal) Free the heat insulation rubber plate [A] from the air suction valve cover [B].
• Remove: Air Suction Valve Cover Bolts [A] Air Suction Valve Cover [B] Air Suction Valve
Air Suction Valve Installation
the air suction valve [A] so that its wider side [B] of • Install the reed valve case faces the front. • Tighten:
Torque - Air Suction Valve Cover Bolts : 9.8 N·m (1.0 kgf·m, 87 in·lb)
• Install the removed parts (see appropriate chapters). Air Suction Valve Inspection
the air suction valve (see Air Suction Valve Re• Remove moval). inspect the reeds for cracks, folds, warps, heat • Visually damage or other damage.
• • •
If there is any doubt as to the condition of the reeds [A], replace the air suction valve as an assembly. Check the reed contact areas [B] of the valve holder for grooves, scratches, any signs of separation from the holder or heat damage. If there is any doubt as to the condition of the reed contact areas, replace the air suction valve as an assembly. If any carbon or other foreign particles have accumulated between the reed and the reed contact area, wash the valve assembly clean with a high-flash point solvent.
CAUTION Do not scrape off the deposits with a scraper as this could damage the rubber, requiring replacement of the suction valve assembly.
5-12 ENGINE TOP END Clean Air System Air Switching Valve Removal
• Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System •
(DFI) chapter) Connector [A] (Disconnect) Separate the hoses [B] from the air suction valve cover and air cleaner housing fitting, and remove the air switching valve [C].
CAUTION Never drop the air switching valve especially on a hardsurface. Such a shock to the air switching valve can damaged it.
Air Switching Valve Installation
is the reverse of removal. • Installation Run the lead hoses correctly (see Cable, Wire, and • Hose Routingand section in the Appendix chapter). • Install the removed parts (see appropriate chapters).
Air Switching Valve Operation Test
to the Air Suction System Damage Inspection in the • Refer Periodic Maintenance chapter.
Air Switching Valve Unit Test
to the Air Switching Valve Unit Test in the Electrical • Refer System chapter.
Clean Air System Hose Inspection
certain that all the hoses are routed without being flat• Be tened or kinked, and are connected correctly to the air cleaner housing, air switching valve and air suction valve cover. If they are not, correct them. Replace them if they are damaged.
ENGINE TOP END 5-13 Cylinder Head Cover Cylinder Head Cover Removal
• Remove: Air Switching Valve (see Air Switching Valve Removal) Stick Coils (see Stick Coil Removal in the Electrical System chapter) Coolant Reserve Tank Bolts (see Coolant Reserve Tank Removal in the Cooling System chapter) Thermostat Housing (see Thermostat Housing Removal in the Cooling System chapter) Water Hose [A] Bolt [B] and Bracket [C] the heat insulation rubber plate [A] from the cylinder • Free head cover.
• Remove: Air Suction Valve Cover [A] (see Air Suction Valve Removal) Cylinder Head Cover Bolts [B] Cylinder Head Cover [C]
Cylinder Head Cover Installation
the head cover gasket with a new one. • Replace Apply silicone sealant [A] to the head cover gasket as • shown in the figure. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004
• Install the new head cover gasket. • Install: Dowel Pins [A] Plug Hole Gaskets [B]
5-14 ENGINE TOP END Cylinder Head Cover the hook [A] of the water pipe [B] in the groove of • Insert the damper [C] as shown in the figure.
•
Damper [D] Install the head cover [E], and tighten the bolts. Torque - Cylinder Head Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
• Install the removed parts (see appropriate chapters).
ENGINE TOP END 5-15 Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below. When removing the tensioner, do not take out the mounting bolts only halfway. Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain. Once the bolts are loosened, the tensioner must be removed and reset as described in "Camshaft Chain Tensioner Installation". Do not turn over the crankshaft while the tensioner is removed. This could upset the camshaft chain timing and damage the valves.
• Remove: Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Cap Bolt [A] (Loosen) Mounting Bolts [B] Chain Tensioner [C]
Camshaft Chain Tensioner Installation
the tensioner cap bolt and O-ring. • Remove While compressing the push rod [A], turn it clockwise with • a suitable screwdriver until the rod stopped.
CAUTION Do not turn the rod counterclockwise at installation. This could detach the rod and the tensioner cannot be reinstalled. the chain tensioner gasket with a new one. • Replace holding the rod in position with a suitable push rod • While holder plate [A] install the tensioner on the cylinder block. 3.5 mm (0.14 in.) [B] 7 mm (0.28 in.) [C] 12 mm (0.47 in.) [D] 8.5 mm (0.33 in.) [E]
5-16 ENGINE TOP END Camshaft Chain Tensioner
• Tighten:
Torque - Camshaft Chain Tensioner Mounting Bolts [A]: 9.8 N·m (1.0 kgf·m, 87 in·lb)
out the holder plate [B]. • Take Install the O-ring and tighten the cap bolt. •
Torque - Camshaft Chain Tensioner Cap Bolt: 5.0 N·m (0.51 kgf·m, 44 in·lb)
ENGINE TOP END 5-17 Camshaft, Camshaft Chain Camshaft Removal
• Remove: Cylinder Head Cover (see Cylinder Head Cover Removal) Plugs Position the crankshaft at #2 piston TDC. ○Using a wrench on the alternator rotor bolt, turn the crankshaft counterclockwise until the "2T" mark [A] on the alternator rotor is aligned with the projection [B] in the inspection window on the alternator cover.
•
• Remove: Camshaft Chain Tensioner (see Camshaft Chain Tensioner Removal) Camshaft Cap Bolts [A] Plates Upper Chain Guide [B] Camshaft Caps [C] Camshafts [D] ○Loosen the camshaft cap bolts as shown sequence [1 ∼ 12] in the figure. Stuff a clean cloth into the chain tunnel to keep any parts from dropping into the crankcase.
•
• Remove: Camshaft Sprocket Bolts [A] Camshaft Sprockets [B]
CAUTION The crankshaft may be turned while the camshafts are removed. Always pull the chain taut while turning the crankshaft. This avoids kinking the chain on the lower (crankshaft) sprocket. A kinked chain could damage both the chain and the sprocket.
5-18 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Installation
the camshaft sprockets as shown in the figure. • Install Inlet Camshaft Sprocket [A] Exhaust Camshaft Sprocket [B]
○The exhaust camshaft has the groove [C].
a non-permanent locking agent to the threads of • Apply the camshaft sprocket bolts and tighten them. Torque - Camshaft Sprocket Bolts: 15 N·m (1.5 kgf·m, 11 ft·lb)
molybdenum disulfide oil solution to all cam parts • Apply and journals. If a new camshaft is to be used, apply a thin coat of molybdenum disulfide grease to the cam surfaces.
NOTE
○Be sure to operate from the engine left side.
the crankshaft at #2 piston TDC (see Camshaft • Position Removal).
CAUTION The crankshaft may be turned while the camshafts are removed. Always pull the chain taut while turning the crankshaft. This avoids kinking the chain on the lower (crankshaft) sprocket. A kinked chain could damage both the chain and the sprocket. the camshaft chain [A] with the camshaft sprock• Engage ets. the tension side (exhaust side) of the chain taut to • Pull install the chain on the sprockets.
○Timing marks [B] align with the cylinder head upper surface. Exhaust Camshaft Sprocket [C] Inlet Camshaft Sprocket [D] ○Count the camshaft chain link pins as shown to verify that the sprocket are positioned correctly.
ENGINE TOP END 5-19 Camshaft, Camshaft Chain the six dowel pins on the marks [A]. • Install Install caps as shown in the figure, noting • the "EX"the[B]camshaft and "IN" [C] marks.
CAUTION The camshaft caps are machined with the cylinder head. So, if a cap is installed in a wrong location, the camshaft may seize because of improper oil clearance in the bearings. the plates on the camshaft caps. •○Install The exhaust side plates [A] is longer the inlet side plates [B].
the upper chain guide [A]. • Install First tighten the all camshaft cap bolts evenly to seat the • camshaft in place, then tighten all bolts following the specified tightening sequence. Torque - Camshaft Cap Bolts: 12 N·m (1.2 kgf·m, 106 in·lb)
•
Plates (EX) [B] Plates (IN) [C] Install the camshaft chain tensioner (see Camshaft Chain Tensioner Installation).
inject [A] the engine oil into 8 places on the cylin• Finally, der head as shown in the figure. the cylinder head cover (see Cylinder Head Cover • Install Installation).
5-20 ENGINE TOP END Camshaft, Camshaft Chain Camshaft, Camshaft Cap Wear Inspection
• Remove: Upper Chain Guide (see Camshaft Removal) • • •
Camshaft Caps (see Camshaft Removal) Cut the strips of plastigauge to journal width. Place a strip on each journal parallel to the camshaft installed in the correct position. Measure each clearance between the camshaft journal and the camshaft cap using the plastigauge (press gauge) [A]. Tighten the camshaft cap bolts (see Camshaft Installation).
NOTE
○Do not turn the camshaft when the plastigauge is between the journal and camshaft cap. Camshaft Journal, Camshaft Cap Clearance Standard: 0.028 ∼ 0.071 mm (0.0011 ∼ 0.0028 in.) Service Limit: 0.16 mm (0.0063 in.)
If any clearance exceeds the service limit, measure the diameter of each camshaft journal with a micrometer. Camshaft Journal Diameter Standard: 23.950 ∼ 23.972 mm (0.9429 ∼ 0.9438 in.) Service Limit: 23.92 mm (0.942 in.)
If the camshaft journal diameter is less than the service limit, replace the camshaft with a new one and measure the clearance again. If the clearance still remains out of the service limit, replace the cylinder head unit.
Camshaft Runout Inspection
the camshafts (see Camshaft Removal). • Remove Set the camshaft in a camshaft alignment jig or on V • blocks. the runout with a dial gauge at the specified • Measure place as shown in the figure. If the runout exceeds the service limit, replace the camshaft. Camshaft Runout Standard: TIR 0.02 mm (0.0008 in.) or less Service Limit: TIR 0.1 mm (0.004 in.)
ENGINE TOP END 5-21 Camshaft, Camshaft Chain Cam Wear Inspection
the camshafts (see Camshaft Removal). • Remove Measure [A] of each cam with a micrometer. • If the camstheareheight worn down past the service limit, replace the camshaft. Cam Height Standard: Exhaust
32.843 ∼ 32.957 mm (1.2930 ∼ 1.2975 in.)
Inlet
33.843 ∼ 33.957 mm (1.3324 ∼ 1.3369 in.)
Service Limit: Exhaust
32.74 mm (1.289 in.)
Inlet
33.74 mm (1.328 in.)
Camshaft Chain Removal
the crankcase (see Crankcase Splitting in the Crank• Split shaft/Transmission chapter). the camshaft chain [A] from the crankshaft • Remove sprocket.
5-22 ENGINE TOP END Cylinder Head Cylinder Compression Measurement NOTE
○Use the battery which is fully charged.
up the engine thoroughly. • Warm the engine. • Stop Remove: • Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Stick Coils (see Stick Coil Removal in the Electrical System chapter) Spark Plugs (see Spark Plug Replacement in the Periodic Maintenance chapter) the compression gauge [A] and adapter [B] firmly • Attach into the spark plug hole. the starter motor, turn the engine over with the throt• Using tle fully open until the compression gauge stops rising; the compression is the highest reading obtainable. Special Tools - Compression Gauge, 20 kgf/cm²: 57001-221 Compression Gauge Adapter, M10 × 1.0: 57001-1317 Cylinder Compression Usable Range: 1 050 ∼ 1 500 kPa (10.7 ∼ 15.3 kgf/cm², 152 ∼ 218 psi) at 500 r/min (rpm)
the measurement for the other cylinder. • Repeat Install the spark plugs. •
Torque - Spark Plugs: 13 N·m (1.3 kgf·m, 115 in·lb)
○The following table should be consulted if the obtainable compression reading is not within the usable range.
Problem Diagnosis Cylinder compression Carbon accumulation on piston and in is higher than usable combustion chamber possibly due to range damaged valve stem oil seal and/or damaged piston oil rings (This may be indicated by white exhaust smoke). Incorrect cylinder head gasket thickness Cylinder compression Gas leakage around cylinder head is lower than usable range Bad condition of valve seating Incorrect valve clearance Incorrect piston/cylinder clearance Piston seizure
Bad condition of piston ring and/or piston ring grooves.
Remedy (Action) Remove the carbon deposits and replace damaged parts if necessary.
Replace the gasket with a standard part. Replace damaged check gasket and cylinder head warp. Repair if necessary. Adjust the valve clearance. Replace the piston and/or cylinder. Inspect the cylinder and replace/repair the cylinder and/or piston as necessary. Replace the piston and/or the piston rings.
ENGINE TOP END 5-23 Cylinder Head Cylinder Head Removal
• Remove: Coolant (Drain,
see Coolant Change in the Periodic Maintenance chapter) Cylinder Head Cover (see Cylinder Head Cover Removal) Camshafts (see Camshaft Removal) Radiator (see Radiator and Radiator Fan Removal in the Cooling System chapter) Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Exhaust Pipe (see Exhaust Pipe Removal)
• Remove the water pipe [A].
• Remove: Front Camshaft Chain Guide [A] Rear Camshaft Chain Guide Bolt [B] Rear Camshaft Chain Guide [C]
• Remove: Engine Mounting Bracket Nuts and Bolts [A] (Both Sides) Engine Mounting Nut [B] and Bolt Engine Mounting Brackets [C] (Both Sides) Oil Hose Banjo Bolt [D]
5-24 ENGINE TOP END Cylinder Head
• Remove: M6 Cylinder Head Bolt [A] M8 Cylinder Head Bolts [B] Cylinder Head
Cylinder Head Installation NOTE
○The camshaft cap is machined with the cylinder head, so if a new cylinder head is installed, use the cap that is supplied with the new head.
a new cylinder head gasket and dowel pins. • Install Replace the cylinder head bolt washers with new ones. • Apply molybdenum oil solution to both sides [A] • of the cylinder headdisulfide bolt washers [B] and the threads of the head bolts [C]. the M8 cylinder head bolts following the tightening • Tighten sequence [1 ∼ 7]. 146 mm (5.75 in.) [1 ∼ 6] 115 mm (4.53 in.) [7]
Torque - Cylinder Head Bolts (M8): 31.4 N·m (3.2 kgf·m, 23.2 ft·lb)
the M6 cylinder head bolt following the tightening • Tighten sequence [8].
Torque - Cylinder Head Bolt (M6): 12 N·m (1.2 kgf·m, 106 in·lb)
ENGINE TOP END 5-25 Cylinder Head
• Install: Front Camshaft Chain Guide [A] •
Rear Camshaft Chain Guide [B] Tighten: Torque - Rear Camshaft Chain Guide Bolt [C]: 17 N·m (1.7 kgf·m, 13 ft·lb)
• Install the removed parts (see appropriate chapters).
Cylinder Head Warp Inspection
the cylinder head. • Clean Lay a straightedge across the lower surface of the cylinder • head at several positions. a thickness gauge [A] to measure the space between • Use the straightedge [B] and the head. Cylinder Head Warp ––– Standard: Service Limit: 0.05 mm (0.002 in.)
If the cylinder head is warped more than the service limit, replace it. If the cylinder head is warped less than the service limit, repair the head by rubbing the lower surface on emery paper secured to a surface plate (first No. 200, then No. 400).
5-26 ENGINE TOP END Valves Valve Clearance Inspection
to the Valve Clearance Inspection in the Periodic • Refer Maintenance chapter.
Valve Clearance Adjustment
to the Valve Clearance Adjustment in the Periodic • Refer Maintenance chapter.
Valve Removal
• Remove: Cylinder Head (see Cylinder Head Removal) Valve Lifter and Shim ○Mark and record the valve lifter and shim locations so they can be installed in their original positions. Using the valve spring compressor assembly, remove the valve.
•
Special Tools - Valve Spring Compressor Assembly [A]: 57001-241 Valve Spring Compressor Adapter, 16 [B]: 57001-1305
Valve Installation
the oil seal with a new one. • Replace Apply engine oil to the lip of the oil seal. • Apply a thin coat molybdenum disulfide grease to the • valve stem beforeofvalve installation. the spring so that the closed coil end faces down• Install wards. Valve Stem [A] Spring Seat [B] Valve Spring (White) [C] Oil Seal [D] Retainer [E] Split Keepers [F] Closed Coil End [G]
Valve Guide Removal
• Remove: Valve (see Valve Removal) •
Oil Seal Spring Seat Heat the area around the valve guide to 120 ∼ 150°C (248 ∼ 302°F), and hammer lightly on the valve guide arbor [A] to remove the guide from the top of the head.
CAUTION Do not heat the cylinder head with a torch. This will warp the cylinder head. Soak the cylinder head in oil and heat the oil. Special Tool - Valve Guide Arbor,
4.5: 57001-1331
ENGINE TOP END 5-27 Valves Valve Guide Installation
engine oil to the valve guide outer surface before • Apply installation. the area around the valve guide hole to about 120 ∼ • Heat 150°C (248 ∼ 302°F).
CAUTION Do not heat the cylinder head with a torch. This will warp the cylinder head. Soak the cylinder head and heat the oil. the valve guide driver [A] and washer [B], press • Using and insert the valve guide in until the washer surface [C] touches the head surface [D]. 15.3 ∼ 15.5 mm (0.60 ∼ 0.61 in.) [E] Special Tools - Valve Guide Driver: 57001-1564 Washer: 57001-1720
until the cylinder head cools down and then ream the • Wait valve guide with the valve guide reamer [A] even if the old guide is reused.
○Turn the reamer in a clockwise direction until the reamer turns freely in the guide. Never turn the reamer counterclockwise or it will be dulled. ○Once the guides are reamed they must be cleaned thoroughly. Special Tool - Valve Guide Reamer,
4.5: 57001-1333
Valve-to-Guide Clearance Measurement (Wobble Method) If a small bore gauge is not available, inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below. Insert a new valve [A] into the guide [B] and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface. Move the stem back and forth [C] to measure valve/valve guide clearance. Repeat the measurement in a direction at a right angle to the first. If the reading exceeds the service limit, replace the guide.
• • •
5-28 ENGINE TOP END Valves NOTE
○The reading is not actual valve/valve guide clearance because the measuring point is above the guide.
Valve/Valve Guide Clearance (Wobble Method) Standard: Exhaust
0.07 ∼ 0.12 mm (0.0028 ∼ 0.0047 in.)
Inlet
0.02 ∼ 0.08 mm (0.0008 ∼ 0.0032 in.)
Service Limit: Exhaust
0.27 mm (0.011 in.)
Inlet
0.23 mm (0.010 in.)
Valve Seat Inspection
the valve (see Valve Removal). • Remove Check the valve seating surface [A] between the valve [B] • and valve seat [C].
○Measure the outside diameter [D] of the seating pattern on the valve seat. If the outside diameter is too large or too small, repair the seat (see Seat Repair). Valve Seating Surface Outside Diameter Standard: Exhaust 19.3 ∼ 19.5 mm (0.7598 ∼ 0.7677 in.) Inlet
21.9 ∼ 22.1 mm (0.8622 ∼ 0.8701 in.)
○Measure the seat width [E] of the portion where there is
no build-up carbon (white portion) of the valve seat with a vernier caliper. Good [F] If the width is too wide [G], too narrow [H] or uneven [J], repair the seat (see Valve Seat Repair). Valve Seating Surface Width Standard: Exhaust
0.5 ∼ 1.0 mm (0.0197 ∼ 0.0394 in.)
Inlet
0.5 ∼ 1.0 mm (0.0197 ∼ 0.0394 in.)
Valve Seat Repair
• Repair the valve seat with the valve seat cutters [A].
Special Tools - Valve Seat Cutter Holder Bar [B]: 57001 -1128 Valve Seat Cutter Holder, 4.5 [C]: 57001 -1330 [For Exhaust Valve Seat] Valve Seat Cutter, 45° -
24.5: 57001-1113
Valve Seat Cutter, 32° -
22: 57001-1206
Valve Seat Cutter, 67.5° -
22: 57001-1207
[For Inlet Valve Seat] Valve Seat Cutter, 45° -
24.5: 57001-1113
Valve Seat Cutter, 32° -
25: 57001-1118
Valve Seat Cutter, 67.5° -
22: 57001-1207
If the manufacturer’s instructions are not available, use the following procedure.
ENGINE TOP END 5-29 Valves Seat Cutter Operation Care 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the diamond particles may fall off. 3. Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface. Also wash off ground particles sticking to the cutter with washing oil.
NOTE
○Do not use a wire brush to remove the metal particles from the cutter. It will take off the diamond particles.
4. Setting the valve seat cutter holder in position, operate the cutter in one hand. Do not apply too much force to the diamond portion.
NOTE
○Prior to grinding, apply engine oil to the cutter and dur-
ing the operation, wash off any ground particles sticking to the cutter with washing oil.
5. After use, wash it with washing oil and apply thin layer of engine oil before storing. Marks Stamped on the Cutter The marks stamped on the back of the cutter [A] represent the following. 60° ........................... Cutter angle [B] 37.5 ....................... Outer diameter of cutter [C]
Operating Procedures Clean the seat area carefully. Coat the seat with machinist’s dye. Fit a 45° cutter into the holder and slide it into the valve guide. Press down lightly on the handle and turn it right or left. Grind the seating surface only until it is smooth.
• • • •
CAUTION Do not grind the seat too much. Overgrinding will reduce valve clearance by sinking the valve into the head. If the valve sinks too far into the head, it will be impossible to adjust the clearance, and the cylinder head must be replaced.
5-30 ENGINE TOP END Valves the outside diameter of the seating surface with • Measure a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the specified range. Widened Width [A] of engagement by machining with 45° cutter Ground Volume [B] by 32° cutter 32° [C] Correct Width [D] Ground Volume [E] by 67.5° cutter 67.5° [F] the outside diameter of the seating surface with • Measure a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind [A] until the diameter is within the specified range. Original Seating Surface [B]
NOTE
○Remove all pittings of flaws from 45° ground surface. ○After grinding with 45° cutter, apply thin coat of machin-
ist’s dye to seating surface. This makes seating surface distinct and 32° and 67.5° grinding operation easier. ○When the valve guide is replaced, be sure to grind with 45° cutter for centering and good contact. If the outside diameter [A] of the seating surface is too large, make the 32° grind described below. If the outside diameter of the seating surface is within the specified range, measure the seat width as described below. Grind the seat at a 32° angle [B] until the seat outside diameter is within the specified range. ○To make the 32° grind, fit a 32° cutter into the holder, and slide it into the valve guide. ○Turn the holder one turn at a time while pressing down very lightly. Check the seat after each turn.
•
CAUTION The 32° cutter removes material very quickly. Check the seat outside diameter frequently to prevent overgrinding.
○After making the 32° grind, return to the seat outside di-
•
ameter measurement step above. To measure the seat width, use a vernier caliper to measure the width of the 45° angle portion of the seat at several places around the seat. If the seat width is too narrow, repeat the 45° grind until the seat is slightly too wide, and then return to the seat outside diameter measurement step above.
ENGINE TOP END 5-31 Valves If the seat width is too wide, make the 67.5° [A] grind described below. If the seat width is within the specified range, lap the valve to the seat as described below. Grind the seat at a 67.5° angle until the seat width is within the specified range. ○To make the 67.5° grind, fit 67.5° cutter into the holder, and slide it into the valve guide. ○Turn the holder, while pressing down lightly. ○After making the 67.5° grind, return to the seat width measurement step above. Correct Width [B]
•
the valve to the seat, once the seat width and outside • Lap diameter are within the ranges specified above.
○Put a little coarse grinding compound on the face of the valve in a number of places around the valve head.
○Spin the valve against the seat until the grinding com-
pound produces a smooth, matched surface on both the seat and the valve. ○Repeat the process with a fine grinding compound. Lapper [A] Valve Seat [B] Valve [C] The seating area should be marked about in the middle of the valve face. If the seat area is not in the right place on the valve, check to be sure the valve is the correct part. If it is, it may have been refaced too much; replace it. Be sure to remove all grinding compound before assembly. When the engine is assembled, be sure to adjust the valve clearance (see Valve Clearance Inspection in the Periodic Maintenance chapter).
• • •
5-32 ENGINE TOP END Valves
ENGINE TOP END 5-33 Cylinder, Pistons Cylinder Removal
• Remove: Cylinder Head (see Cylinder Head Removal) Bolt [A] Water Pipe [B] Water Hose Fitting [C] Cylinder [D]
Cylinder Installation NOTE
○If a new cylinder is used, use a new piston ring.
the dowel pins [A] and new cylinder gasket [B]. • Install Apply • bore. molybdenum disulfide oil solution to the cylinder
piston ring openings must be positioned as shown in • The the figure. The openings of the oil ring steel rails must be about 30 ∼ 40° of angle from the opening of the top ring. Top Ring [A] Second Ring [B] Upper Oil Ring Steel Rail [C] Lower Oil Ring Steel Rail [D] Oil Ring Expander [E] Hollow [F] 30 ∼ 40° [G]
the piston base [A] to hold piston level as shown in • Slip the figure, and install the cylinder. Special Tool - Piston Base,
Piston Removal
2.3: 57001-1336
the cylinder (see Cylinder Removal). • Remove Place a clean cloth under the pistons and remove the pis• ton pin snap ring [A] from the outside of each piston.
5-34 ENGINE TOP END Cylinder, Pistons
• Remove the piston pins.
Special Tool - Piston Pin Puller Assembly [A]: 57001-910
• Remove the pistons.
spread the ring opening with your thumbs and • Carefully then push up on the opposite side of the ring [A] to remove
•
it. Remove the 3-piece oil ring with your thumbs in the same manner.
Piston Installation
molybdenum disulfide oil solution to the oil ring ex• Apply pander, and install the oil ring expander [A] in the bottom piston ring groove so the ends [B] not butt together. Apply molybdenum disulfide oil solution to the oil ring steel rails, and install the oil ring steel rails, one above the expander and one below it. ○Spread the rail with your thumbs, but only enough to fit the rail over the piston. ○Release the rail into the bottom piston ring groove.
•
NOTE
○The oil ring rails have no "top" or "bottom". not mix up the top and second ring. • Do the top ring [A] so that the "R" mark [B] faces up. • Install Install the second ring [C] so that the "RN" mark [D] faces • up.
○Apply rings.
molybdenum disulfide oil solution to the piston
ENGINE TOP END 5-35 Cylinder, Pistons NOTE
○If a new piston is used, use new piston ring.
the piston with its marking hollow facing forward. • Install Fit a new pin snap ring into the side of the piston • so that thepiston ring opening [A] does not coincide with the slit [B] of the piston pin hole. ○Apply molybdenum disulfide oil solution to the piston pins and piston journals. ○When installing the piston pin snap ring, compress it only enough to install it and no more.
CAUTION Do not reuse snap rings, as removal weakens and deforms them. They could fall out and score the cylinder wall.
• Install the cylinder (see Cylinder Installation). Cylinder Wear Inspection
there is a difference in cylinder wear in different di• Since rections, take a side-to-side and a front-to-back measurement at each of the two locations (total of four measurements) shown in the figure. If any of the cylinder inside diameter measurements exceeds the service limit, replace the cylinder. 10 mm (0.39 in.) [A] 60 mm (2.36 in.) [B] Cylinder Inside Diameter Standard: 62.000 ∼ 62.012 mm (2.4409 ∼ 2.4414 in.) Service Limit: 62.10 mm (2.4449 in.)
Piston Wear Inspection
the outside diameter [A] of each piston 5 mm • Measure (0.20 in.) [B] up from the bottom of the piston at a right angle to the direction of the piston pin. If the measurement is under service limit, replace the piston. Piston Diameter Standard: 61.942 ∼ 61.957 mm (2.4387 ∼ 2.4392 in.) Service Limit: 61.79 mm (2.4327 in.)
5-36 ENGINE TOP END Cylinder, Pistons Piston Ring, Piston Ring Groove Wear Inspection
for uneven groove wear by inspecting the ring seat• Check ing.
•
The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings. With the piston rings in their grooves, make several measurements with a thickness gauge [A] to determine piston ring/groove clearance. Piston Ring/Groove Clearance Standard: Top
0.03 ∼ 0.07 mm (0.0012 ∼ 0.0028 in.)
Second
0.02 ∼ 0.06 mm (0.0008 ∼ 0.0024 in.)
Service Limit: Top
0.17 mm (0.0067 in.)
Second
0.16 mm (0.0063 in.)
Piston Ring Groove Width Inspection
the piston ring groove width. •○Measure Use a vernier caliper at several points around the piston. Piston Ring Groove Width Standard: Top [A]
0.82 ∼ 0.84 mm (0.0323 ∼ 0.0331 in.)
Second [B] 0.81 ∼ 0.83 mm (0.0319 ∼ 0.0327 in.) Service Limit: Top
0.92 mm (0.0362 in.)
Second
0.91 mm (0.0358 in.)
If the width of any of the two grooves is wider than the service limit at any point, replace the piston.
Piston Ring Thickness Inspection
the piston ring thickness. •○Measure Use the micrometer to measure at several points around the ring.
Piston Ring Thickness Standard: Top [A]
0.77 ∼ 0.79 mm (0.0303 ∼ 0.0311 in.)
Second [B] 0.77 ∼ 0.79 mm (0.0303 ∼ 0.0311 in.) Service Limit: Top
0.70 mm (0.028 in.)
Second
0.70 mm (0.028 in.)
If any of the measurements is less than the service limit on either of the rings, replace all the rings.
NOTE
○When using new rings in a used piston, check for un-
even groove wear. The rings should fit perfectly parallel to the groove sides. If not, replace the piston.
ENGINE TOP END 5-37 Cylinder, Pistons Piston Ring End Gap Inspection
the piston ring [A] inside the cylinder, using the pis• Place ton to locate the ring squarely in place. Set it close to the
•
bottom of the cylinder, where cylinder wear is low. Measure the gap [B] between the ends of the ring with a thickness gauge. Piston Ring End Gap Standard: Top
0.15 ∼ 0.30 mm (0.0059 ∼ 0.0118 in.)
Second
0.40 ∼ 0.55 mm (0.0157 ∼ 0.0217 in.)
Oil
0.20 ∼ 0.80 mm (0.0079 ∼ 0.0315 in.)
Service Limit: Top
0.6 mm (0.024 in.)
Second
0.9 mm (0.035 in.)
Oil
1.1 mm (0.043 in.)
If the end gap of either ring is greater than the service limit, replace all the rings.
Boring, Honing Performance When boring and honing a cylinder, note the following: ○There is one size of oversize piston available. Oversize piston require oversize rings. Oversize Pistons and Rings + 0.5 mm (0.020 in.)
○Before boring a cylinder, first measure the exact diameter
of the oversize piston, and then, according to the standard clearance in the Specifications section, determine the rebore diameter. However, if the amount of boring necessary would make the inside diameter greater than 0.5 mm (0.020 in.) oversize, the cylinder block must be replaced. ○Cylinder inside diameter must not vary more than 0.01 mm (0.0004 in.) at any point. ○Be wary of measurements taken immediately after boring since the heat affects cylinder diameter. ○In the case of a rebored cylinder and oversize piston, the service limit for the cylinder is the diameter that the cylinder was bored to plus 0.1 mm (0.004 in.) and the service limit for the piston is the oversize piston original diameter minus 0.15 mm (0.0059 in.). If the exact figure for the rebored diameter is unknown, it can be roughly determined by measuring the diameter at the base of the cylinder. ○Never separate the liner from the cylinder, because the top surface of cylinder and liner is machined at the factory as an assembly.
5-38 ENGINE TOP END Throttle Body Assy Holder Throttle Body Assy Holder Installation
the groove [A] of the throttle body holder to the projec• Fit tion [B] of the cylinder head. the clamps [C] as shown in the figure. • Install Tighten: •
Torque - Throttle Body Assy Holder Clamp Screws: 2.0 N·m (0.20 kgf·m, 18 in·lb)
ENGINE TOP END 5-39 Muffler WARNING To avoid a serious burn, do not remove the muffler when the engine is still hot. Wait until the muffler cool down.
Muffler Body Removal
• Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Muffler Cover Clamp Bolt [A] and Clamp Muffler Cover Clamp Screw [B] Muffler Cover Bolts [C] Muffler Cover [D]
• Remove: Clamp Bolt [A] (Loosen) Mounting Nut and Bolt [B] Muffler Body [C]
Muffler Body Installation
the muffler body gasket [A] with a new one. • Replace the muffler body gasket so that its chamfer side [B] • Install faces front [C]. Rear [D]
the muffler body and mounting bolt. • Install Install • figure. the muffler body clamp bolt [A] as shown in the
•
74 ∼ 84° [B] More than 15 mm (0.59 in.) [C] Swingarm [D] Tighten:
Torque - Muffler Body Mounting Bolt: 30 N·m (3.1 kgf·m, 22 ft·lb) Muffler Body Clamp Bolt: 17 N·m (1.7 kgf·m, 13 ft·lb)
5-40 ENGINE TOP END Muffler If the pad [A] was removed, install it as shown in the figure. Muffler Cover [B] 1 ∼ 5 mm (0.04 ∼ 0.20 in.) [C]
the claw [A] into the cover clamp [B] and tighten the • Insert clamp screw [C] as shown in the figure. About 15° [D] Torque - Muffler Cover Clamp Screw: 6.9 N·m (0.70 kgf·m, 61 in·lb)
• Tighten:
Torque - Muffler Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
the hole [A] of the clamp [B] to the hook [C] of the • Fit muffler cover [D]. • Tighten: Torque - Muffler Cover Clamp Bolt [E]: 9.8 N·m (1.0 kgf·m, 87 in·lb)
warm up the engine, wait until the engine • Thoroughly cools down, retighten all the bolts and screw. • Install the removed parts (see appropriate chapters).
Exhaust Pipe Removal
• Remove: Muffler Body (see Muffler Body Removal) Oxygen Sensor (see Oxygen Sensor Removal in the Electrical System chapter) Mounting Bolt [A]
ENGINE TOP END 5-41 Muffler
• Remove: Exhaust Pipe Holder Nuts [A] Exhaust Pipe [B]
Exhaust Pipe Installation
the exhaust pipe gaskets with new ones. • Replace Install the • Tighten: exhaust pipe. •
Torque - Exhaust Pipe Holder Nuts: 12 N·m (1.2 kgf·m, 106 in·lb) Exhaust Pipe Mounting Bolt: 9.8 N·m (1.0 kgf·m, 87 in·lb)
• Install the removed parts (see appropriate chapters).
CLUTCH 6-1
Clutch Table of Contents Exploded View........................................................................................................................ Specifications ......................................................................................................................... Special Tool and Sealant ........................................................................................................ Clutch Lever and Cable .......................................................................................................... Clutch Lever Free Play Inspection .................................................................................... Clutch Lever Free Play Adjustment .................................................................................. Clutch Cable Removal ...................................................................................................... Clutch Cable Installation ................................................................................................... Clutch Cable Lubrication................................................................................................... Clutch Lever Installation.................................................................................................... Clutch Cover........................................................................................................................... Clutch Cover Removal ...................................................................................................... Clutch Cover Installation ................................................................................................... Release Shaft Removal .................................................................................................... Release Shaft Installation ................................................................................................. Clutch Cover Disassembly................................................................................................ Clutch Cover Assembly..................................................................................................... Clutch ..................................................................................................................................... Clutch Removal................................................................................................................. Clutch Installation.............................................................................................................. Clutch Plate Wear and Damage Inspection ...................................................................... Clutch Plate Warp Inspection............................................................................................ Clutch Spring Free Length Inspection...............................................................................
6-2 6-4 6-5 6-6 6-6 6-6 6-6 6-6 6-6 6-6 6-7 6-7 6-7 6-7 6-7 6-8 6-8 6-9 6-9 6-9 6-11 6-11 6-11
6
6-2 CLUTCH Exploded View
CLUTCH 6-3 Exploded View No. 1 2 3 4 5
Fastener Clutch Cover Bolts Clutch Hub Nut Clutch Lever Clamp Bolt Clutch Spring Bolts Oil Filler Plug
CL: Apply cable lubricant. EO: Apply engine oil. G: Apply grease. M: Apply molybdenum disulfide grease. R: Replacement Parts Si: Apply silicone grease. W: Apply water.
N·m 9.8 132 8.8 8.8 –
Torque kgf·m 1.0 13.5 0.90 0.90 –
ft·lb 87 in·lb 97.4 78 in·lb 78 in·lb –
Remarks
Hand-Tighten
6-4 CLUTCH Specifications Item Clutch Lever Free Play Clutch Friction Plate Thickness Friction and Steel Plate Warp Clutch Spring Free Length
Standard 2 ∼ 3 mm (0.08 ∼ 0.12 in.)
Service Limit – – –
2.92 ∼ 3.08 mm (0.115 ∼ 0.121 in.) 0.15 mm (0.0059 in.) or less 39.4 mm (1.55 in.)
2.6 mm (0.10 in.) 0.3 mm (0.012 in.) 37.6 mm (1.48 in.)
Clutch Housing Gear Selection when Replacing Clutch Housing Gear Crankshaft Primary Gear Marking A A A A B B B B C C C D D
Clutch Housing Color
Gear Marking
Color
Part Number
White White White White Red Red Red Red None None None Yellow Yellow
A B C D A B C D B C D C D
White Red None Yellow White Red None Yellow Red None Yellow None Yellow
13095-0095 13095-0096 13095-0097 13095-0098 13095-0095 13095-0096 13095-0097 13095-0098 13095-0096 13095-0097 13095-0098 13095-0097 13095-0098
CLUTCH 6-5 Special Tool and Sealant Clutch Holder: 57001-1243
Kawasaki Bond (Silicone Sealant): 92104-0004
6-6 CLUTCH Clutch Lever and Cable Clutch Lever Free Play Inspection
to the Clutch Operation Inspection in the Periodic • Refer Maintenance chapter.
Clutch Lever Free Play Adjustment
to the Clutch Operation Inspection in the Periodic • Refer Maintenance chapter.
Clutch Cable Removal
the right lower fairing (see Lower Fairing Re• Remove moval in the Frame chapter). the locknut [A] at the clutch lever, and screw in • Loosen the adjuster [B]. up the slots [C] in the clutch lever, locknut and ad• Line juster, and then free the cable from the lever.
the dust cover [A] at the clutch cable lower end out • Slide of place. the clutch cable lower from the cable holder [B] • Remove loosening the locknuts [C]. the clutch inner cable tip from the clutch release • Free lever. • Pull the clutch cable out of the frame.
Clutch Cable Installation
the clutch cable correctly (see Cable, Wire, and Hose • Run Routing section in the Appendix chapter). the clutch cable (see Clutch Operation Inspection • Adjust in the Periodic Maintenance chapter).
Clutch Cable Lubrication
to the Chassis Parts Lubrication in the Periodic • Refer Maintenance chapter.
Clutch Lever Installation
the clutch lever so that the mating surface [A] of the • Install clutch lever is aligned with the punch mark [B]. • Tighten: Torque - Clutch Lever Clamp Bolt: 8.8 N·m (0.90 kgf·m, 78 in·lb)
CLUTCH 6-7 Clutch Cover Clutch Cover Removal
• Remove: Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Clutch Cable Lower End [A] Clutch Cover Bolts [B]
the release lever [A] toward the rear as shown in the • Turn figure, and remove the clutch cover [B]. About 90° [C]
Clutch Cover Installation
silicone sealant to the area [A] where the mating • Apply surface of the crankcase touches the clutch cover gasket. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004
the clutch cover gasket with a new one. • Replace Tighten the clutch cover bolts. •
Torque - Clutch Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
Release Shaft Removal CAUTION Do not remove the clutch release lever and shaft assembly unless it is absolutely necessary. If removed, the oil seal replacement may be required. the clutch cover (see Clutch Cover Removal). • Remove the lever and shaft assembly straight out of the clutch • Pull cover.
Release Shaft Installation
grease to the oil seal lips on the upper ridge of the • Apply clutch cover. engine oil to the needle bearing in the hole of the • Apply clutch cover. molybdenum disulfide grease to the pusher-holding • Apply portion on the release shaft. the release shaft straight into the upper hole of the • Insert clutch cover.
CAUTION When inserting the release shaft, be careful not to remove the spring of the oil seal.
6-8 CLUTCH Clutch Cover Clutch Cover Disassembly
• Remove: Oil Seal [A]
Needle Bearing [B] Oil Level Gauge
Clutch Cover Assembly
• Replace the needle bearing and oil seal with new ones. ○Install
NOTE
the needle bearing so that the manufacture’s mark face out.
the needle bearing [A] and oil seal [B] position as • Install shown in the figure.
•
Press the needle bearing so that the bearing surface [C] is flush with the housing end of clutch cover [D]. Press the oil seal until the bottom [E]. Install the oil level gauge until the bottom.
CLUTCH 6-9 Clutch Clutch Removal
• Remove: Clutch Cover (see Clutch Cover Removal) Clutch Spring Bolts [A] Clutch Springs Clutch Spring Plate [B] (with Bearing and Pusher [C])
• Remove: Friction Plates and Steel Plates Clutch Hub Nut [A] Holding the clutch hub [B], remove the nut and washer. ○ Special Tool - Clutch Holder [C]: 57001-1243
• Remove: Clutch Hub
Spacer Needle Bearing Bushing Clutch Housing Thrust Spacer
Clutch Installation
the thrust spacer [A] so that the chamfer side [B] • Install faces inward.
the bushing [A] and needle bearing [B]. •○Install Install the snap ring [C] on the bushing so that it faces inward.
the clutch housing, spacer, clutch hub, washer and • Install clutch hub nut.
○Holding the clutch hub, tighten the clutch hub nut. Special Tool - Clutch Holder: 57001-1243
Torque - Clutch Hub Nut: 132 N·m (13.5 kgf·m, 97.4 ft·lb)
6-10 CLUTCH Clutch the clutch housing is replaced with a new one, select the • Ifproper clutch housing in accordance with the combination
•
of the clutch housing gear and crankshaft primary gear markings with colors. Crankshaft Primary Gear [A] Clutch Housing Gear [B] Be sure to confirm the marking and color on the clutch housing gear.
Clutch Housing Gear Selection when Replacing Clutch Housing Gear Crankshaft
Clutch Housing
Primary Gear Marking [C]
Color [D]
Gear Marking [E]
Color [F]
Part Number
A
White
A
White
13095-0095
A
White
B
Red
13095-0096
A
White
C
None
13095-0097
A
White
D
Yellow
13095-0098
B
Red
A
White
13095-0095
B
Red
B
Red
13095-0096
B
Red
C
None
13095-0097
B
Red
D
Yellow
13095-0098
C
None
B
Red
13095-0096
C
None
C
None
13095-0097
C
None
D
Yellow
13095-0098
D
Yellow
C
None
13095-0097
D
Yellow
D
Yellow
13095-0098
the friction plate first and steel plate, and afterward • Install install them alternately.
○The inner-end [A] and outer-end [B] friction plate blocks are wider than the others. Wider [C] Narrower [D]
CLUTCH 6-11 Clutch engine oil to the bearing, and install it. • Apply Apply molybdenum disulfide grease to the pusher ends. • Install the clutch spring plate [A] with the pusher [B]. •
• Install the springs and tighten the clutch spring bolts.
Torque - Clutch Spring Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)
• Install the clutch cover (see Clutch Cover Installation). Clutch Plate Wear and Damage Inspection
inspect the friction and steel plates for signs of • Visually seizure, overheating (discoloration), or uneven wear. the thickness of each friction plate [A] at several • Measure points. If any plates show signs of damage, or if they have worn past the service limit, replace them with new ones. Friction Plate Thickness Standard: 2.92 ∼ 3.08 mm (0.115 ∼ 0.121 in.) Service Limit:
2.6 mm (0.10 in.)
Clutch Plate Warp Inspection
each friction plate or steel plate on a surface plate • Place and measure the gap between the surface plate [A] and each friction plate or steel plate [B] with a thickness gauge [C]. The gap is the amount of friction or steel plate warp. If any plate is warped over the service limit, replace it with a new one. Friction and Steel Plate Warp Standard: 0.15 mm (0.0059 in.) or less Service Limit:
0.3 mm (0.012 in.)
Clutch Spring Free Length Inspection
the free length of the clutch springs [A]. • Measure If any spring is shorter than the service limit, it must be replaced. Clutch Spring Free Length Standard: 39.4 mm (1.55 in.) Service Limit:
37.6 mm (1.48 in.)
ENGINE LUBRICATION SYSTEM 7-1
Engine Lubrication System Table of Contents Exploded View........................................................................................................................ Engine Oil Flow Chart............................................................................................................. Specifications ......................................................................................................................... Special Tools and Sealant ...................................................................................................... Engine Oil and Oil Filter.......................................................................................................... Oil Level Inspection........................................................................................................... Engine Oil Change............................................................................................................ Oil Filter Replacement ...................................................................................................... Bypass Valve Disassembly ............................................................................................... Bypass Valve Assembly.................................................................................................... Bypass Valve Cleaning and Inspection............................................................................. Oil Screen Cleaning and Inspection.................................................................................. Oil Pressure Relief Valve........................................................................................................ Oil Pressure Relief Valve Removal ................................................................................... Oil Pressure Relief Valve Installation ................................................................................ Oil Pressure Relief Valve Inspection................................................................................. Oil Pump................................................................................................................................. Oil Pump Removal ............................................................................................................ Oil Pump Installation ......................................................................................................... Oil Pump Inspection.......................................................................................................... Oil Pressure Measurement..................................................................................................... Oil Pressure Measurement ............................................................................................... Oil Pressure Switch ................................................................................................................ Oil Pressure Switch Removal ........................................................................................... Oil Pressure Switch Installation ........................................................................................
7-2 7-4 7-5 7-6 7-7 7-7 7-7 7-7 7-8 7-8 7-8 7-8 7-9 7-9 7-9 7-9 7-10 7-10 7-10 7-10 7-11 7-11 7-12 7-12 7-12
7
7-2 ENGINE LUBRICATION SYSTEM Exploded View
ENGINE LUBRICATION SYSTEM 7-3 Exploded View No. 1 2 3 4 5 6 7 8 9 10 11 12 13
Fastener Crankcase Oil Passage Plug Engine Oil Drain Bolt (Crankcase) Engine Oil Drain Bolt (Oil Screen Cover) Oil Breather Mounting Bolts Oil Filter Mounting Bolt Oil Hose Banjo Bolts Oil Passage Plugs Oil Pipe Banjo Bolt Oil Pressure Relief Valve Oil Pressure Switch Oil Pressure Switch Terminal Bolt Oil Pump Mounting Bolts Oil Screen Cover Bolts
EO: Apply engine oil. G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts SS: Apply silicone sealant.
N·m 15 19.6 19.6 9.8 19.6 19.6 20 12 15 15 1.5 9.8 9.8
Torque kgf·m 1.5 2.0 2.0 1.0 2.0 2.0 2.0 1.2 1.5 1.5 0.15 1.0 1.0
ft·lb 11 14.5 14.5 87 in·lb 14.5 14.5 15 106 in·lb 11 11 13 in·lb 87 in·lb 87 in·lb
Remarks
L
L L SS G L
7-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart
ENGINE LUBRICATION SYSTEM 7-5 Specifications Item Engine Oil Type Viscosity Capacity
Level Oil Pressure Measurement Oil Pressure
Standard API SE, SF or SG API SH, SJ or SL with JASO MA SAE 10W-40 1.3 L (1.4 US qt) (when filter is not removed) 1.6 L (1.7 US qt) (when filter is removed) 1.7 L (1.8 US qt) (when engine is completely dry) Between upper and lower level lines (Wait 2 ∼ 3 minutes after idling or running) 98 ∼ 147 kPa (1.0 ∼ 1.5 kgf/cm², 14 ∼ 21 psi) at 4 000 r/min (rpm), Oil Temperature 90°C (194°F)
7-6 ENGINE LUBRICATION SYSTEM Special Tools and Sealant Outside Circlip Pliers: 57001-144
Oil Pressure Gauge Adapter, M18 × 1.5: 57001-1278
Oil Pressure Gauge, 10 kgf/cm²: 57001-164
Kawasaki Bond (Silicone Sealant): 56019-120
ENGINE LUBRICATION SYSTEM 7-7 Engine Oil and Oil Filter WARNING Motorcycle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine or transmission seizure, accident, and injury.
Oil Level Inspection
that the engine oil level is between the upper [A] • Check and lower [B] levels in the gauge.
NOTE
○Situate the motorcycle so that it is perpendicular to the
ground. ○If the motorcycle has just been used, wait several minutes for all the oil to drain down. ○If the oil has just been changed, start the engine and run it for several minutes at idle speed. This fills the oil filter with oil. Stop the engine, then wait several minutes until the oil settles.
CAUTION Racing the engine before the oil reaches every part can cause engine seizure. If the engine oil gets extremely low or if the oil pump or oil passages clog up or otherwise do not function properly, the oil pressure warning indicator light will light. If this light stays on when the engine is running above idle speed, stop the engine immediately and find the cause. If the oil level is too high, remove the excess oil, using a syringe or some other suitable device. If the oil level is too low, add the correct amount of oil through the oil filler opening. Use the same type and make of oil that is already in the engine.
NOTE
○If the engine oil type and make are unknown, use any brand of the specified oil to top off the level in preference to running the engine with the oil level low. Then at your earliest convenience, change the oil completely.
Engine Oil Change
to the Engine Oil Change in the Periodic Mainte• Refer nance chapter.
Oil Filter Replacement
to the Oil Filter Replacement in the Periodic Main• Refer tenance chapter.
7-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter Bypass Valve Disassembly
the oil filter (see Oil Filter Replacement in the • Remove Periodic Maintenance chapter).
NOTE
○Oil draining is not necessary, but place the oil pan under the oil filter because oil drain a little at the oil filter removal.
the retaining pin [A] out of the oil filter mounting bolt • Drive [B]. • Drop out the spring [C] and the bypass valve steel ball [D].
Bypass Valve Assembly
the bypass valve steel ball into the oil filter mounting • Drop bolt. the spring into the oil filter mounting bolt and com• Put press it beyond the small hole. the retaining pin into the small hole to hold the • Drive spring. the oil filter (see Oil Filter Replacement in the Pe• Install riodic Maintenance chapter).
Bypass Valve Cleaning and Inspection
the bypass valve (see Bypass Valve Disas• Disassemble sembly). • Clean the bypass valve parts in a high-flash point solvent.
WARNING
Clean the parts in a well-ventilated area, and take care that there is no spark or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvent. inspect the bypass valve parts. • Visually If there is any damaged part, replace it.
Oil Screen Cleaning and Inspection
the bolts [A] and oil screen cover [B]. • Remove Clean the screen [C] with high-flash point solvent and • remove anyoilparticles stuck to it.
WARNING Clean the screen in a well-ventilated area, and take care that there is no spark or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvent.
NOTE
○While cleaning the screen, check for any metal particles that might indicate internal engine damage.
the screen carefully for any damage; holes and • Check broken wires. If the screen is damaged, replace the oil screen.
ENGINE LUBRICATION SYSTEM 7-9 Oil Pressure Relief Valve Oil Pressure Relief Valve Removal
the clutch cover (see Clutch Cover Removal in • Remove the Clutch chapter). the oil pressure relief valve [A] from the • Unscrew crankcase.
Oil Pressure Relief Valve Installation
a non-permanent locking agent to the threads of • Apply the relief valve, and tighten it.
CAUTION Do not apply too much non-permanent locking agent to the threads. This may block the oil passage. Torque - Oil Pressure Relief Valve: 15 N·m (1.5 kgf·m, 11 ft·lb)
Oil Pressure Relief Valve Inspection
to see if the valve [A] slides smoothly when push• Check ing it in with a wooden or other soft rod, and see if it comes back to its seat by spring [B] pressure.
NOTE
○Inspect the valve in its assembled state. Disassembly and assembly may change the valve performance. If any rough spots are found during above inspection, wash the valve clean with a high-flash point solvent and blow out any foreign particles that may be in the valve with compressed air.
WARNING Clean the oil pressure relief valve in a well -ventilated area, and take care that there is no spark or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvent. If cleaning does not solve the problem, replace the oil pressure relief valve as an assembly. The oil pressure relief valve is precision made with no allowance for replacement of individual parts.
7-10 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump Removal
• Remove: Clutch (see Clutch Removal in the Clutch chapter) Oil Pump Mounting Bolts [A] Oil Pump [B]
Oil Pump Installation
the oil pump with engine oil for initial lubrication. • Fill Turn the oil pump shaft so that the projection [A] in its shaft • fits into the slot [B] of the water pump shaft. a non-permanent locking agent to the threads of • Apply the oil pump mounting bolts, and tighten them. Torque - Oil Pump Mounting Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
Oil Pump Inspection
inspect the oil pump body, inner and outer rotors • Visually and cover. If there is any damage or uneven wear, replace the oil pump as an assembly.
ENGINE LUBRICATION SYSTEM 7-11 Oil Pressure Measurement Oil Pressure Measurement
the right lower fairing (see Lower Fairing Re• Remove moval in the Frame chapter). the oil passage plug, and attach the adapter [A] • Remove and gauge [B] to the plug hole. Special Tools - Oil Pressure Gauge, 10 kgf/cm²: 57001-164 Oil Pressure Gauge Adapter, M18 × 1.5: 57001-1278
the engine and warm up the engine. • Start Run the at the specified speed, and read the oil • pressureengine gauge. If the reading is much lower than the standard, check the oil pump, relief valve, and/or crankshaft bearing insert wear immediately. If the reading is much higher than the standard, check the oil passages for clogging. Oil Pressure Standard: 98 ∼ 147 kPa (1.0 ∼ 1.5 kgf/cm², 14 ∼ 21 psi) at 4 000 r/min (rpm), Oil Temperature 90°C (194°F)
the engine. • Stop Remove the oil pressure gauge and adapter. •
WARNING
Take care against burns form hot engine oil that will drain through the oil passage when the gauge adapter is removed.
• Tighten:
Torque - Crankcase Oil Passage Plug: 15 N·m (1.5 kgf·m, 11 ft·lb)
7-12 ENGINE LUBRICATION SYSTEM Oil Pressure Switch Oil Pressure Switch Removal
• Remove: Left Lower Fairing (see Lower Fairing Removal in the Frame chapter) Switch Cover [A] Switch Terminal Bolt [B] Oil Pressure Switch [C]
Oil Pressure Switch Installation
silicone sealant to the threads of the oil pressure • Apply switch, and tighten it. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Torque - Oil Pressure Switch: 15 N·m (1.5 kgf·m, 11 ft·lb)
the switch lead [A] as shown in the figure. • Install 45° [B]
• •
Front [C] Apply grease to the terminal. Tighten the terminal bolt. Torque - Oil Pressure Switch Terminal Bolt: 1.5 N·m (0.15 kgf·m, 13 in·lb)
the switch. • Cover Install the left lower fairing (see Lower Fairing Installation • in the Frame chapter).
ENGINE REMOVAL/INSTALLATION 8-1
Engine Removal/Installation Table of Contents Exploded View........................................................................................................................ Engine Removal/Installation ................................................................................................... Engine Removal................................................................................................................ Engine Installation.............................................................................................................
8-2 8-4 8-4 8-5
8
8-2 ENGINE REMOVAL/INSTALLATION Exploded View
ENGINE REMOVAL/INSTALLATION 8-3 Exploded View No. 1 2
Fastener Engine Mounting Bracket Bolts and Nuts Engine Mounting Nuts
N·m 69 69
Torque kgf·m 7.0 7.0
ft·lb 51 51
Remarks
8-4 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation Engine Removal
the rear part of the swingarm with a stand. • Support Squeeze • [A]. the brake lever slowly and hold it with a band
WARNING Be sure to hold the front brake when removing the engine, or the motorcycle may fall over. It could cause an accident and injury.
CAUTION Be sure to hold the front brake when removing the engine, or the motorcycle may fall over. The engine or the motorcycle could be damaged.
• Remove: Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter) Lower Fairings (see Lower Fairing Removal in the Frame chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Clutch Cable Lower End (see Clutch Cable Removal in the Clutch chapter) Coolant Reserve Tank (see Coolant Reserve Tank Removal in the Cooling System chapter) Radiator (see Radiator and Radiator Fan Removal in the Cooling System chapter) Exhaust Pipe (see Exhaust Pipe Removal in the Engine Top End chapter) Air Switching Valve (see Air Switching Valve Removal in the Engine Top End chapter) Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Shift Lever (see Shift Pedal Removal in the Crankshaft/Transmission chapter) Engine Sprocket (see Engine Sprocket Removal in the Final Drive chapter) Regulator/Rectifier (see Regulator/Rectifier Inspection in the Electrical System chapter)
• Remove: Oil Pressure Switch Lead [A] Neutral Switch Lead Connector [B] Breather Hose End [C]
ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation
• Remove: Starter Motor Cable [A] Engine Ground Cable Terminal Bolt [B] Alternator and Crankshaft Sensor Lead Connectors (see Alternator Cover Removal in the Electrical System chapter) Stick Coil Lead Connectors (see Stick Coil Removal in the Electrical System chapter)
the engine with a suitable stand [A]. •○Support Put a plank [B] onto the suitable stand for engine balance.
• Remove: Engine Mounting Bracket Nuts and Bolts [A] (Both Sides) Engine Mounting Nut [B] and Bolt Engine Mounting Brackets [C] (Both Sides)
• Remove: Engine Mounting Nuts [A] and Bolts Engine [B]
Engine Installation
the engine with a suitable stand. •○Support Put a plank onto the suitable stand for engine balance.
8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation the heat insulation rubber plate as shown in the • Install figure.
A: After installation, set the projection in the hole. B: To Radiator C: To Fan Motor Lead D: To Air Suction Valve Cover E: To Stick Coils F: To Water Pipe G: To Throttle Body Assy Holders H: To Breather Hose the lower engine mounting bolt [A] first while sup• Insert porting the engine. Then insert the upper engine mounting bolt [B], and tighten the nuts lightly.
ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation tightening the mounting nuts, install the engine • Before mounting brackets. When inserting the front engine
•
mounting bolt, use the suitable stand under the engine to lift it. Tighten: Torque - Engine Mounting Bracket Bolts and Nuts: 69 N·m (7.0 kgf·m, 51 ft·lb) Engine Mounting Nuts: 69 N·m (7.0 kgf·m, 51 ft·lb)
the leads, cables and hoses correctly (see Cable, • Run Wire, and Hose Routing section in the Appendix chapter). the removed parts (see appropriate chapters). • Install Adjust: • Throttle Cables (see Throttle Control System Inspection
• •
in the Periodic Maintenance chapter) Clutch Cable (see Clutch Operation Inspection in the Periodic Maintenance chapter) Drive Chain (see Drive Chain Slack Inspection in the Periodic Maintenance chapter) Fill the engine with engine oil (see Engine Oil Change in the Periodic Maintenance chapter). Fill the engine with coolant (see Coolant Change in the Periodic Maintenance chapter).
CRANKSHAFT/TRANSMISSION 9-1
Crankshaft/Transmission Table of Contents Exploded View................................... Specifications .................................... Special Tools and Sealant ................. Crankcase ........................................ Crankcase Splitting ...................... Crankcase Assembly ................... Crankshaft and Connecting Rods...... Crankshaft Removal .................... Crankshaft Installation ................. Connecting Rod Removal ............ Connecting Rod Installation ......... Crankshaft/Connecting Rod Cleaning .................................... Connecting Rod Bend Inspection Connecting Rod Twist Inspection. Connecting Rod Big End Side Clearance Inspection ................ Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection.................................. Crankshaft Side Clearance Inspection.................................. Crankshaft Runout Inspection...... Crankshaft Main Bearing Insert/Journal Wear Inspection . Starter Motor Clutch .......................... Starter Motor Clutch Removal/Installation.................. Starter Motor Clutch Inspection ... Starter Motor Clutch Disassembly
9-2 9-6 9-9 9-10 9-10 9-11 9-14 9-14 9-14 9-15 9-15 9-16 9-17 9-17 9-17 9-18 9-19 9-20 9-20 9-22 9-22 9-22 9-22
Starter Motor Clutch Assembly .... Balancer ............................................ Balancer Removal........................ Balancer Installation..................... Balancer Shaft Bearing Insert/Journal Wear Inspection . Transmission ..................................... Shift Pedal Removal .................... Shift Pedal Installation ................. External Shift Mechanism Removal .................................... External Shift Mechanism Installation ................................. External Shift Mechanism Inspection.................................. Transmission Shaft Removal ....... Transmission Shaft Installation .... Transmission Shaft Disassembly . Transmission Shaft Assembly...... Shift Drum and Fork Removal...... Shift Drum and Fork Installation... Shift Drum Disassembly............... Shift Drum Assembly ................... Shift Fork Bending Inspection ...... Shift Fork/Gear Groove Wear Inspection.................................. Shift Fork Guide Pin/Drum Groove Wear Inspection ........... Gear Dog and Gear Dog Hole Damage Inspection ...................
9-22 9-23 9-23 9-23 9-23 9-25 9-25 9-25 9-26 9-26 9-26 9-27 9-27 9-28 9-28 9-31 9-31 9-32 9-32 9-32 9-33 9-33 9-33
9
9-2 CRANKSHAFT/TRANSMISSION Exploded View
CRANKSHAFT/TRANSMISSION 9-3 Exploded View No. 1 2 3 4 5 6 7
Fastener Connecting Rod Big End Nuts Crankcase Bolts (M8, L = 90 mm) Crankcase Bolts (M8, L = 73 mm) Crankcase Bolts (M6) Oil Breather Mounting Bolts Shift Drum Bearing Holder Bolts Starter Motor Clutch Bolts
N·m 27.5 24 19 12 9.8 12 34.3
Torque kgf·m 2.8 2.4 1.9 1.2 1.0 1.2 3.5
ft·lb 20 18 14 106 in·lb 87 in·lb 106 in·lb 25
G: Apply grease. L: Apply a non-permanent locking agent. LG: Apply liquid gasket. M: Apply molybdenum disulfide grease. MO: Apply molybdenum disulfide oil solution. (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1) R: Replacement Parts S: Follow the specified tightening sequence. SS: Apply silicone sealant.
Remarks MO MO, S MO, S L L L
9-4 CRANKSHAFT/TRANSMISSION Exploded View
CRANKSHAFT/TRANSMISSION 9-5 Exploded View No. 1 2 3 4 5 6 7
Fastener Neutral Switch Shift Drum Pin Plate Bolt Shift Drum Positioning Bolt Shift Lever Bolt Shift Pedal Mounting Bolt Shift Shaft Return Spring Pin Tie-Rod Locknuts
EO: Apply engine oil. G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts
N·m 15 9.0 24.5 12 25 19.6 7.0
Torque kgf·m 1.5 0.92 2.5 1.2 2.5 2.0 0.71
ft·lb 11 80 in·lb 18 106 in·lb 18 14.5 62 in·lb
Remarks
L
L
9-6 CRANKSHAFT/TRANSMISSION Specifications Item Crankshaft, Connecting Rods Connecting Rod Bend
Standard –––
Connecting Rod Twist
–––
Connecting Rod Big End Side Clearance
0.13 ∼ 0.38 mm (0.0051 ∼ 0.0150 in.) 0.031 ∼ 0.059 mm (0.0012 ∼ 0.0023 in.) 29.984 ∼ 30.000 mm (1.1805 ∼ 1.1811 in.)
Connecting Rod Big End Bearing Insert/Crankpin Clearance Crankpin Diameter: Marking None
29.984 ∼ 29.994 mm (1.1805 ∼ 1.1809 in.) 29.995 ∼ 30.000 mm ○ (1.1809 ∼ 1.1811 in.) Connecting Rod Big End Inside Diameter: 33.000 ∼ 33.016 mm (1.2992 ∼ 1.2998 in.) Marking None 33.000 ∼ 33.008 mm (1.2992 ∼ 1.2995 in.) 33.009 ∼ 33.016 mm ○ (1.2996 ∼ 1.2998 in.) Connecting Rod Big End Bearing Insert Thickness: Brown 1.480 ∼ 1.485 mm (0.05827 ∼ 0.05846 in.) Black 1.485 ∼ 1.490 mm (0.05846 ∼ 0.05866 in.) Blue 1.489 ∼ 1.494 mm (0.05862 ∼ 0.05882 in.) Crankshaft Side Clearance 0.05 ∼ 0.20 mm (0.0020 ∼ 0.0079 in.) Crankshaft Runout TIR 0.02 mm (0.0008 in.) or less Crankshaft Main Bearing Insert/Journal 0.014 ∼ 0.038 mm Clearance (0.0006 ∼ 0.0015 in.) Crankshaft Main Journal Diameter: 27.984 ∼ 28.000 mm (1.1017 ∼ 1.1024 in.) Marking None 27.984 ∼ 27.992 mm (1.1017 ∼ 1.1020 in.) 1 27.993 ∼ 28.000 mm (1.1021 ∼ 1.1024 in.) Crankcase Main Bearing Inside Diameter: 31.000 ∼ 31.016 mm (1.2205 ∼ 1.2211 in.)
Service Limit TIR 0.2/100 mm (0.008/3.94 in.) TIR 0.2/100 mm (0.008/3.94 in.) 0.58 mm (0.023 in.) 0.10 mm (0.004 in.) 29.97 mm (1.1799 in.) – – – – – – – – –
– – – – – –
– – – – – – – – – 0.40 mm (0.0157 in.) TIR 0.05 mm (0.0020 in.) 0.07 mm (0.0028 in.) 27.96 mm (1.101 in.) – – – – – – – – –
CRANKSHAFT/TRANSMISSION 9-7 Specifications Item
Standard
Service Limit
Marking
○
None
31.000 ∼ 31.008 mm (1.2205 ∼ 1.2208 in.) 31.009 ∼ 31.016 mm (1.2208 ∼ 1.2211 in.)
Crankshaft Main Bearing Insert Thickness: Black 1.495 ∼ 1.499 mm (0.05885 ∼ 0.05902 in.) Blue 1.499 ∼ 1.503 mm (0.05902 ∼ 0.05917 in.) Yellow 1.503 ∼ 1.507 mm (0.05917 ∼ 0.05933 in.) Balancer 0.020 ∼ 0.044 mm Balancer Shaft Bearing Insert/Journal Clearance (0.0008 ∼ 0.0017 in.) Balancer Shaft Journal Diameter: 25.984 ∼ 26.000 mm (1.0230 ∼ 1.0236 in.) Marking None 25.984 ∼ 25.994 mm (1.0230 ∼ 1.0234 in.) 25.995 ∼ 26.000 mm ○ (1.0234 ∼ 1.0236 in.) Crankcase Main Bearing Inside Diameter: 29.000 ∼ 29.016 mm (1.1417 ∼ 1.1424 in.) Marking 29.000 ∼ 29.008 mm ○ (1.1417 ∼ 1.1420 in.) None 29.009 ∼ 29.016 mm (1.1421 ∼ 1.1424 in.) Balancer Shaft Bearing Insert Thickness: Brown 1.495 ∼ 1.499 mm (0.05885 ∼ 0.05902 in.) Black 1.499 ∼ 1.503 mm (0.05902 ∼ 0.05917 in.) Blue 1.503 ∼ 1.507 mm (0.05917 ∼ 0.05933 in.) Transmission 4.9 ∼ 5.0 mm Shift Fork Ear Thickness (0.193 ∼ 0.197 in.) 5.05 ∼ 5.15 mm Gear Groove Width (0.199 ∼ 0.203 in.) Shift Fork Guide Pin Diameter 5.9 ∼ 6.0 mm (0.232 ∼ 0.236 in.) 6.05 ∼ 6.20 mm Shift Drum Groove Width (0.238 ∼ 0.244 in.)
– – – – – –
– – – – – – – – –
0.07 mm (0.0028 in.) 25.96 mm (1.022 in.) – – – – – – – – –
– – – – – –
– – – – – – – – –
4.8 mm (0.189 in.) 5.3 mm (0.209 in.) 5.8 mm (0.228 in.) 6.3 mm (0.248 in.)
9-8 CRANKSHAFT/TRANSMISSION Specifications Connecting Rod Big End Bearing Insert Selection Con-rod Big End Inside Diameter Marking
Bearing Insert
Crankpin Diameter Marking
Size Color
Part Number
None
○
Brown
92028-1494
None
None
○
Black
92028-1493
None
Blue
92028-1492
○ ○
Crankshaft Main Bearing Insert Selection Crankcase Main Crankpin Main Bearing Inside Journal Diameter Diameter Marking Marking
○ ○
None
None
1
None
None
Bearing Insert* Size Color
Part Number
Journal Nos.
Black
92028-1487 92028-1490
1, 3 2
92028-1486
1, 3
92028-1489 92028-1582 92028-1586
2 1, 3 2
1
Blue Yellow
*: The bearing insert for Nos. 2 journal have an oil groove.
Balancer Shaft Bearing Insert Selection Crankcase Main Bearing Inside Diameter Marking
Balancer Shaft Journal Diameter Marking
Bearing Insert Size Color
Part Number
○ ○
○
Brown
92028-1424
None
None
○
Black
92028-1423
None
None
Blue
92028-1422
Crankshaft Selection when Replacing Crankshaft Clutch Housing Gear Marking
Color
A A B B B C C C C D D D D
White White Red Red Red None None None None Yellow Yellow Yellow Yellow
Crankshaft Primary Gear Marking A B A B C A B C D A B C D
Color
Part Number
White Red White Red None White Red None Yellow White Red None Yellow
13031-0111 13031-0112 13031-0111 13031-0112 13031-0113 13031-0111 13031-0112 13031-0113 13031-0114 13031-0111 13031-0112 13031-0113 13031-0114
CRANKSHAFT/TRANSMISSION 9-9 Special Tools and Sealant Bearing Puller: 57001-135
Bearing Puller Adapter: 57001-317
Outside Circlip Pliers: 57001-144
Kawasaki Bond(Liquid Gasket - Black): 92104-1064
9-10 CRANKSHAFT/TRANSMISSION Crankcase Crankcase Splitting
the engine (see Engine Removal in the Engine • Remove Removal/Installation chapter). the engine on a clean surface and hold the engine • Set steady while parts are being removed. • Remove: Clutch (see Clutch Removal in the Clutch chapter) External Shift Mechanism (see External Shift Mechanism Removal) Oil Pump (see Oil Pump Removal in the Engine Lubrication System chapter) Starter Motor (see Starter Motor Removal in the Electrical System chapter) Alternator Rotor (see Alternator Rotor Removal in the Electrical System chapter) Water Pump (see Water Pump Removal in the Cooling System chapter) Oil Filter (see Oil Filter Replacement in the Periodic Maintenance chapter) Oil Screen (see Oil Screen Cleaning and Inspection in the Engine Lubrication System chapter) Cylinder Head (see Cylinder Head Removal in the Engine Top End chapter) Cylinder (see Cylinder Removal in the Engine Top End chapter) If the crankshaft is to be removed, remove the pistons (see Piston Removal in the Engine Top End chapter).
• Remove the upper crankcase bolts [A].
the lower crankcase bolts. •○Remove First loosen the M6 bolts [A].
•
M8 Bolts [B] Tap lightly around the crankcase mating surface with a plastic mallet, and split the crankcase. Take care not to damage the crankcase.
CRANKSHAFT/TRANSMISSION 9-11 Crankcase Crankcase Assembly CAUTION The upper and lower crankcase halves are machined at the factory in the assembled state, so the crankcase halves must be replaced as a set. a high-flash point solvent, clean off the mating sur• With faces of the crankcase halves and wipe dry. compressed air, blow out the oil passages in the • Using crankcase halves. engine oil to the new O-ring [A]. • Apply a non-permanent locking agent to the threads of • Apply the oil breather mounting bolts [B] and tighten them. Torque - Oil Breather Mounting Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
the breather hose [C] as shown in the figure. • Install About 34.5 mm (1.36 in.) [D]
the O-rings [A] with new ones. • Replace grease to the new O-rings. • Apply Install the oil passage pipe [B] as shown in the figure. • Slit (Horizontal) [C] 70° [D] (1 mm (0.04 in.) Hole direction) Lower Crankcase [E]
9-12 CRANKSHAFT/TRANSMISSION Crankcase
• Install: Shift Drum (see Shift Drum and Fork Installation) Shift Forks and Shift Rods (see Shift Drum and Fork Installation) Crankshaft (see Crankshaft Installation) Balancer Shaft (see Balancer Installation) Connecting Rods (see Connecting Rod Installation) Camshaft Chain Transmission Shafts and Gears (see Transmission Shaft Installation) Dowel Pins [A] Before fitting the lower case on the upper case, check the following. ○Be sure to hang the camshaft chain on the crankshaft. ○Check to see that the shift drum and transmission gears are in the neutral position.
•
liquid gasket [A] to the mating surface of the lower • Apply crankcase half. Sealant - Kawasaki Bond (Liquid Gasket - Black): 92104 -1064
CAUTION Do not apply liquid gasket around the crankshaft main bearing inserts, and oil passage holes.
• Fit the lower crankcase to the upper crankcase.
molybdenum disulfide oil solution to the seating sur• Apply face [A] and threads [B] of the M8 bolts.
CRANKSHAFT/TRANSMISSION 9-13 Crankcase the lower crankcase bolts using the following • Tighten steps.
○Following the sequence numbers on the lower crankcase half, tighten the M8 bolts [1 ∼ 7] L= 90 mm (3.54 in.).
Torque - Crankcase Bolts (M8): 24 N·m (2.4 kgf·m, 18 ft·lb)
○Tighten the M8 bolts [8 ∼ 9] L= 73 mm (2.87 in.).
Torque - Crankcase Bolts (M8): 19 N·m (1.9 kgf·m, 14 ft·lb)
○Tighten the M6 bolts.
Torque - Crankcase Bolts (M6): 12 N·m (1.2 kgf·m, 106 in·lb) L = 135 mm (5.31 in.) [A] L = 85 mm (3.35 in.) [B] (with New Copper Washer) L = 60 mm (2.36 in.) [C] L = 38 mm (1.50 in.) [D]
• Tighten the upper crankcase bolts in the order listed.
Torque - Crankcase Bolts (M6): 12 N·m (1.2 kgf·m, 106 in·lb) L= 85 mm (3.35 in.) [A] L= 60 mm (2.36 in.) [B] (with New Copper Washer)
tightening all crankcase bolts, check the following • After items.
○Wipe
up the liquid gasket that seeps out around the crankcase mating surface. ○Crankshaft and transmission shafts turn freely. ○While spinning the output shaft, gears shift smoothly from the 1st to 6th gear, and 6th to 1st. ○When the output shaft stays still, the gear can not be shifted to 2nd gear or other higher gear positions. Install the removed parts (see appropriate chapters).
•
9-14 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft Removal
the crankcase (see Crankcase Splitting). • Split Removal the crankshaft [A]. •
Crankshaft Installation
the crankshaft is replaced with a new one, select the • Ifproper crankshaft in accordance with the combination
•
of the crankshaft primary gear and clutch housing gear markings with colors. Crankshaft Primary Gear [A] Clutch Housing Gear [B] Be sure to confirm the marking and color on the crankshaft primary gear.
Crankshaft Selection when Replacing Crankshaft Clutch Housing Gear Marking [E]
Color [F]
A A B B B C C C C D D D D
White White Red Red Red None None None None Yellow Yellow Yellow Yellow
Crankshaft Primary Gear Marking [C] A B A B C A B C D A B C D
Color [D]
Part Number
White Red White Red None White Red None Yellow White Red None Yellow
13031-0111 13031-0112 13031-0111 13031-0112 13031-0113 13031-0111 13031-0112 13031-0113 13031-0114 13031-0111 13031-0112 13031-0113 13031-0114
CRANKSHAFT/TRANSMISSION 9-15 Crankshaft and Connecting Rods NOTE
○If the crankshaft is replaced with a new one, refer to the Connecting Rod Big End Bearing Insert Selection in the Specifications.
CAUTION If the crankshaft, bearing inserts, or crankcase halves are replaced with new ones, select the bearing inserts and check clearance with a plastigage (press gauge) before assembling engine to be sure the correct bearing inserts are installed. the crankshaft. •○Install Align the timing mark [A] on the balancer drive gear [B]
•
with the timing mark [C] on the balancer gear [D]. Apply molybdenum disulfide oil solution to the crankshaft main bearing inserts.
Connecting Rod Removal
the crankcase (see Crankcase Splitting). • Split Remove: • Connecting Rod Big End Nuts [A] Crankshaft
NOTE
○Mark and record the locations of the connecting rods and their big end caps so that they can be reassembled in their original positions.
• Remove the connecting rods from the crankshaft. CAUTION
Discard the connecting rod bolts. To prevent damage to the crankpin surfaces, do not allow the connecting rod bolts to bump against the crankpins.
Connecting Rod Installation CAUTION To minimize vibration, the connecting rods should have the same weight mark. Big End Cap [A] Connecting Rod [B] Weight Mark, Alphabet [C] Diameter Mark (Around Weight Mark) [D]: "○" or no mark
9-16 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods CAUTION If the connecting rods, big end bearing inserts, or crankshaft are replaced with new ones, select the bearing insert and check clearance with a plastigage (press gauge) before assembling engine to be sure the correct bearing inserts are installed.
CAUTION The connecting rod bolts are designed to stretch when tightened. Never reuse them. the connecting rod big end bolts and nuts with • Replace new ones. molybdenum disulfide oil solution to the inner sur• Apply faces of upper and lower bearing inserts [A]. not apply any grease or oil to the cap inside and cap • Do insert outside [B]. the inserts so that their nails [C] are on the same • Install side and fit them into the recess of the connecting rod and cap.
CAUTION Wrong application of oil and grease could cause bearing damage.
○When installing the inserts [A], be careful not to damage
• • •
the insert surface with the edge of the connecting rod [B] or the cap [C]. One way to install inserts is as follows. Installation [D] to Cap Installation [E] to Connecting Rod Push [F] Spare Dowel Pin [G] Connecting Rod Bolts [H] Install the cap on the connecting rod, aligning the weight and diameter marks. Remove debris and clean the surface of inserts. Apply molybdenum disulfide oil solution [MO] to the threads and seating surfaces of the big end nuts and bolts.
the crankshaft (see Crankshaft Installation). • Install Install each • Tighten: connecting rod on its original crankpin. •
Torque - Connecting Rod Big End Nuts: 27.5 N·m (2.8 kgf·m, 20 ft·lb)
Crankshaft/Connecting Rod Cleaning
removing the connecting rods from the crankshaft, • After clean them with a high-flash point solvent. the crankshaft oil passages with compressed air to • Blow remove any foreign particles or residue that may have accumulated in the passages.
CRANKSHAFT/TRANSMISSION 9-17 Crankshaft and Connecting Rods Connecting Rod Bend Inspection
the connecting rod big end bearing inserts, and • Remove reinstall the connecting rod big end cap. an arbor [A] of the same diameter as the connect• Select ing rod big end, and insert the arbor through the connect-
• • •
ing rod big end. Select an arbor of the same diameter as the piston pin and at least 100 mm (3.94 in.) long, and insert the arbor [B] through the connecting rod small end. On a surface plate, set the big-end arbor on V block [C]. With the connecting rod held vertically, use a height gauge to measure the difference in the height of the arbor above the surface plate over a 100 mm (3.94 in.) length to determine the amount of connecting rod bend. If the connecting rod bend exceeds the service limit, the connecting rod must be replaced. Connecting Rod Bend Service Limit: TIR 0.2/100 mm (0.008/3.94 in.)
Connecting Rod Twist Inspection
the big-end arbor [A] still on V block [C], hold the • With connecting rod horizontally and measure the amount that the arbor [B] varies from being paralleled with the surface plate over a 100 mm (3.94 in.) length of the arbor to determine the amount of connecting rod twist. If the connecting rod twist exceeds the service limit, the connecting rod must be replaced. Connecting Rod Twist Service Limit: TIR 0.2/100 mm (0.008/3.94 in.)
Connecting Rod Big End Side Clearance Inspection
the connecting rod big end side clearance. •○Measure Insert a thickness gauge [A] between the big end and either crank web to determine clearance.
Connecting Rod Big End Side Clearance Standard: 0.13 ∼ 0.38 mm (0.0051 ∼ 0.0150 in.) Service Limit: 0.58 mm (0.023 in.)
If the clearance exceeds the service limit, replace the connecting rod with new one and then check the clearance again. If the clearance is too large after connecting rod replacement, the crankshaft also must be replaced.
9-18 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection
the bearing insert/crankpin [A] clearance with • Measure plastigage [B]. the big end nuts to the specified torque (see Con• Tighten necting Rod Installation).
NOTE
○Do not move the connecting rod and crankshaft during clearance measurement.
Connecting Rod Big End Bearing Insert/Crankpin Clearance Standard: 0.031 ∼ 0.059 mm (0.0012 ∼ 0.0023 in.) Service Limit: 0.10 mm (0.004 in.)
If the clearance is within the standard, no bearing replacement is required. If the clearance is between 0.059 mm (0.0023 in.) and the service limit 0.10 mm (0.004 in.), replace the bearing inserts [A] with inserts painted blue [B]. Check the insert/crankpin clearance with the plastigage. The clearance may exceed the standard slightly, but it must not be less than the minimum in order to avoid bearing seizure. If the clearance exceeds the service limit, measure the diameter of the crankpins. Crankpin Diameter Standard: 29.984 ∼ 30.000 mm (1.1805 ∼ 1.1811 in.) Service Limit: 29.97 mm (1.1799 in.)
If any crankpin has worn past the service limit, replace the crankshaft with a new one. If the measured crankpin diameters are not less than the service limit, but do not coincide with the original diameter markings on the crankshaft, make new marks on it. Crankpin Diameter Marks None: 29.984 ∼ 29.994 mm (1.1805 ∼ 1.1809 in.)
○:
29.995 ∼ 30.000 mm (1.1809 ∼ 1.1811 in.)
◊: Crankpin Diameter Marks, "○" or no mark.
CRANKSHAFT/TRANSMISSION 9-19 Crankshaft and Connecting Rods the connecting rod big end inside diameter, and • Measure mark each connecting rod big end in accordance with the
•
inside diameter. Tighten the connecting rod big end nuts to the specified torque (see Connecting Rod Installation).
NOTE
○The mark already on the big end should almost coincide with the measurement.
Connecting Rod Big End Inside Diameter Marks None: 33.000 ∼ 33.008 mm (1.2992 ∼ 1.2995 in.)
○:
33.009 ∼ 33.016 mm (1.2996 ∼ 1.2998 in.)
Big End Cap [A] Connecting Rod [B] Weight Mark, Alphabet [C] Diameter Mark (Around Weight Mark) [D]: "○" or no mark the proper bearing insert [A] in accordance with the • Select combination of the connecting rod and crankshaft coding. Size Color [B] Bearing Insert
Con-rod Big End Inside Diameter Marking
Crankpin Diameter Marking
Size Color
Part Number
None
○
Brown
92028-1494
None
None
○ ○
○
Black
92028-1493
None
Blue
92028-1492
the new inserts in the connecting rod and check • Install insert/crankpin clearance with the plastigage.
Crankshaft Side Clearance Inspection
a thickness gauge [A] between the crankcase main • Insert bearing and the crank web at the No. 2 journal [B] to determine clearance. If the clearance exceeds the service limit, replace the crankcase halves as a set.
NOTE
○The upper and lower crankcase halves are machined at the factory in the assembled state, so the crankcase halves must be replaced as a set. Crankshaft Side Clearance Standard: 0.05 ∼ 0.20 mm (0.0020 ∼ 0.0079 in.) Service Limit: 0.40 mm (0.0157 in.)
9-20 CRANKSHAFT/TRANSMISSION Crankshaft and Connecting Rods Crankshaft Runout Inspection
the crankshaft runout. • Measure If the measurement exceeds the service limit, replace the crankshaft. Crankshaft Runout Standard: TIR 0.02 mm (0.0008 in.) or less Service Limit: TIR 0.05 mm (0.0020 in.)
Crankshaft Main Bearing Insert/Journal Wear Inspection
a plastigage (press gauge), measure the bearing • Using insert/journal [B] clearance [A].
NOTE
○Tighten the crankcase bolts to the specified torque (see Crankcase Assembly). ○Do not turn the crankshaft during clearance measurement. ○Journal clearance less than 0.025 mm (0.00098 in.) can not be measured by plastigage, however, using genuine parts maintains the minimum standard clearance. Crankshaft Main Bearing Insert/Journal Clearance Standard: 0.014 ∼ 0.038 mm (0.0006 ∼ 0.0015 in.) Service Limit: 0.07 mm (0.0028 in.)
If the clearance is within the standard, no bearing replacement is required. If the clearance is between 0.038 mm (0.0015 in.) and the service limit 0.07 mm (0.0028 in.), replace the bearing inserts [A] with inserts painted blue [B]. Check insert/journal clearance with the plastigage. The clearance may exceed the standard slightly, but it must not be less than the minimum in order to avoid bearing seizure. If the clearance exceeds the service limit, measure the diameter of the crankshaft main journal. Crankshaft Main Journal Diameter Standard: 27.984 ∼ 28.000 mm (1.1017 ∼ 1.1024 in.) Service Limit: 27.96 mm (1.101 in.)
If any journal has worn past the service limit, replace the crankshaft with a new one. If the measured journal diameters are not less than the service limit, but do not coincide with the original diameter markings on the crankshaft, make new marks on it. Crankshaft Main Journal Diameter Marks None: 27.984 ∼ 27.992 mm (1.1017 ∼ 1.1020 in.) 1:
□:
27.993 ∼ 28.000 mm (1.1021 ∼ 1.1024 in.)
Crankshaft Main Journal Diameter Marks, "1" or no mark.
CRANKSHAFT/TRANSMISSION 9-21 Crankshaft and Connecting Rods the main bearing inside diameter, and mark the • Measure upper crankcase half in accordance with the inside diameter. A: Crankcase Main Bearing Inside Diameter Marks, "○" or no mark.
NOTE
○Tighten the crankcase bolts to the specified torque (see Crankcase Assembly).
○The mark already on the upper crankcase half should almost coincide with the measurement.
Crankcase Main Bearing Inside Diameter Marks 31.000 ∼ 31.008 mm (1.2205 ∼ 1.2208 in.) :
○
None: 31.009 ∼ 31.016 mm (1.2208 ∼ 1.2211 in.)
the proper bearing insert [A] in accordance with the • Select combination of the crankcase and crankshaft coding. Size Color [B]
Crankcase Main Bearing Inside Diameter Marking
Crankpin Main Journal Diameter Marking
Bearing Insert* Size Color
Part Number
Journal Nos.
○ ○
1
Black
92028-1487 92028-1490
1, 3 2
None
92028-1486
1, 3
None
1
None
None
92028-1489 92028-1582 92028-1586
2 1, 3 2
Blue Yellow
*: The bearing insert for Nos. 2 journal have an oil groove. the new inserts in the crankcase halves and check • Install insert/journal clearance with the plastigage.
9-22 CRANKSHAFT/TRANSMISSION Starter Motor Clutch Starter Motor Clutch Removal/Installation
to the Alternator Rotor Removal/Installation in the • Refer Electrical System chapter.
Starter Motor Clutch Inspection
• Remove: Alternator Cover (see Alternator Cover Removal in the • •
Electrical System chapter) Starter Idle Gear and shaft Turn the starter motor clutch gear [A] by hand. The starter motor clutch gear should turn clockwise [B] freely, but should not turn counterclockwise [C]. If the starter motor clutch does not operate as it should or if it makes noise, go to the next step. Disassemble the starter motor clutch, and visually inspect the clutch parts. If there is any worn or damaged part, replace it.
NOTE
○Examine the starter motor clutch gear as well. Replace it if it worn or damaged.
Starter Motor Clutch Disassembly
• Remove: Alternator Rotor (see Alternator Rotor Removal in the Electrical System chapter) Starter Motor Clutch Bolts [A] Starter Motor Clutch [B]
Starter Motor Clutch Assembly
a non-permanent locking agent to the threads of • Apply the starter motor clutch bolts and tighten them. Torque - Starter Motor Clutch Bolts: 34.3 N·m (3.5 kgf·m, 25 ft·lb)
CRANKSHAFT/TRANSMISSION 9-23 Balancer Balancer Removal
the crankcase (see Crankcase Splitting). • Split Remove the balancer shaft [A] with the balancer gear. •
Balancer Installation
the balancer shaft. •○Install Align the timing mark [A] on the balancer gear [B] with the
•
timing mark [C] on the balancer drive gear [D]. Apply molybdenum disulfide oil solution to the balancer shaft bearing inserts.
Balancer Shaft Bearing Insert/Journal Wear Inspection
the bearing insert/journal [A] clearance with • Measure plastigage [B].
NOTE
○Tighten the crankcase bolts to the specified torque (see Crankcase Assembly). ○Do not turn the balancer shaft during clearance measurement. ○Journal clearance less than 0.025 mm (0.00098 in.) can not be measured by plastigage, however, using genuine parts maintains the minimum standard clearance. Balancer Shaft Bearing Insert/Journal Clearance Standard: 0.020 ∼ 0.044 mm (0.0008 ∼ 0.0017 in.) Service Limit: 0.07 mm (0.0028 in.)
If the clearance is within the standard, no bearing replacement is required. If the clearance is between 0.044 mm (0.0017 in.) and the service limit 0.07 mm (0.0028 in.), replace the bearing inserts [A] with inserts painted blue [B]. Check insert/journal clearance with the plastigage. The clearance may exceed the standard slightly, but it must not be less than the minimum in order to avoid bearing seizure. If the clearance exceeds the service limit, measure the diameter of the balancer shaft journal. Balancer Shaft Journal Diameter Standard: 25.984 ∼ 26.000 mm (1.0230 ∼ 1.0236 in.) Service Limit: 25.96 mm (1.022 in.)
9-24 CRANKSHAFT/TRANSMISSION Balancer If any journal has worn past the service limit, replace the balancer shaft with a new one. If the measured journal diameters are not less than the service limit, but do not coincide with the original diameter markings [A] on the balancer shaft, make new marks on it. Balancer Shaft Journal Diameter Marks None: 25.984 ∼ 25.994 mm (1.0230 ∼ 1.0234 in.)
○:
25.995 ∼ 26.000 mm (1.0234 ∼ 1.0236 in.)
: Balancer Shaft Journal Diameter Marks, "○" or no mark. the main bearing inside diameter, and mark the • Measure upper crankcase half in accordance with the inside diameter. A: Crankcase Main Bearing Inside Diameter Marks, "○" or no mark.
NOTE
○Tighten the crankcase bolts to the specified torque (see Crankcase Assembly). ○The mark already on the upper crankcase half should almost coincide with the measurement. Crankcase Main Bearing Inside Diameter Marks 29.000 ∼ 29.008 mm (1.1417 ∼ 1.1420 in.) :
○
None: 29.009 ∼ 29.016 mm (1.1421 ∼ 1.1424 in.)
the proper bearing insert [A] in accordance with the • Select combination of the crankcase and balancer shaft coding. Size Color [B] Crankcase Main Bearing Inside Diameter Marking
○ ○
Balancer Shaft Journal Diameter Marking
○ None
Bearing Insert Size Color
Part Number
Brown
92028-1424
None
○
Black
92028-1423
None
None
Blue
92028-1422
the new inserts in the crankcase and check in• Install sert/journal clearance with the plastigage.
CRANKSHAFT/TRANSMISSION 9-25 Transmission Shift Pedal Removal
• Remove: Shift Pedal Mounting Bolt [A] Shift Lever Bolt [B] Shift Pedal [C] with Shift Lever
Shift Pedal Installation
grease to the shift pedal [A]. • Apply Install • Tighten:the washers [B] and shift pedal. •
Torque - Shift Pedal Mounting Bolt [C]: 25 N·m (2.5 kgf·m, 18 ft·lb)
the mark [A] on the shift shaft with the mark [B] on • Align the shift lever. • Tighten: Torque - Shift Lever Bolt: 12 N·m (1.2 kgf·m, 106 in·lb)
the shift pedal [C] as shown in the figure. • Install About 16° [D]
○To adjust the pedal position, loosen the front locknut [E]
•
(left-hand threads) and rear locknut [F] and then turn the tie-rod [G]. Tighten: Torque - Tie-Rod Locknuts: 7.0 N·m (0.71 kgf·m, 62 in·lb)
9-26 CRANKSHAFT/TRANSMISSION Transmission sure the sealing lip of the rubber boots [A] fits into the • Be groove of the ball joint after installing the shift lever link. Correctly Boot Fitting Position [B] Incorrectly Boot Fitting Position [C]
External Shift Mechanism Removal
• Remove: Engine Oil (Drain, see Engine Oil Change in the Periodic •
Maintenance chapter) Shift Lever (see Shift Pedal Removal) Clutch (see Clutch Removal in the Clutch chapter) Spread the shift mechanism arm [A] and over shift limiter [B] out of the shift drum [C], and pull out the shift shaft assembly [D].
External Shift Mechanism Installation
that the return spring [A] and pawl spring [B] are • Check properly fitted on the mechanism. the shift shaft assembly. • Install Place the mechanism arm [C] and over shift limiter • [D] on the shift shift drum pins. • Install the removed parts (see appropriate chapters).
External Shift Mechanism Inspection
the shift shaft [A] for any damage. • Examine If the shaft is bent, straighten or replace it. If the splines [B] are damaged, replace the shaft. If the return spring [C] or pawl spring [D] is damaged in any way, replace them. If the shift mechanism arm [E] or over shift limiter [F] is damaged in any way, replace the shaft.
CRANKSHAFT/TRANSMISSION 9-27 Transmission the return spring pin [A] is not loose. • Check If it is loose, unscrew it, apply a non-permanent locking agent to the threads, and tighten it. Torque - Shift Shaft Return Spring Pin: 19.6 N·m (2.0 kgf·m, 14.5 ft·lb)
inspect the shift drum pins [A], pin holder [B] and • Visually pin plate [C]. If they are badly worn or if they show any damage, replace them.
Transmission Shaft Removal
the crankcase (see Crankcase Splitting). • Split Remove the drive shaft [A] and output shaft [B]. •
Transmission Shaft Installation
to see that the set pins [A] and set rings [B] are in • Check place.
the drive shaft and output shaft into the upper • Install crankcase half. engine oil to the bearings. •○Apply The bearing set pins and rings must match properly with
the holes or grooves in the bearing outer races. When they are properly matched, there is no clearance [A] between the crankcase and the bearing outer races.
9-28 CRANKSHAFT/TRANSMISSION Transmission the crankcase (see Crankcase Assembly). • Assemble Press in the [A] onto collar [B] so that the surface • of the oil sealoilis seal flush with the counterbore bottom surface [C] of the crankcase.
○Apply grease to the oil seal lips.
Transmission Shaft Disassembly
the transmission shafts (see Transmission Shaft • Remove Removal). the circlips, disassemble the transmission • Remove shafts. Special Tool - Outside Circlip Pliers: 57001-144
5th gear [A] on the output shaft has three steel balls • The assembled into it for the positive neutral finder mechanism. Remove the 5th gear. ○Set the output shaft in a vertical position holding the 3rd gear [B]. ○Spin the 5th gear quickly [C] and pull it off upward.
• Remove the ball bearing [A] from each shafts.
Special Tools - Bearing Puller [B]: 57001-135 Bearing Puller Adapter [C]: 57001-317
• Discard the bearing.
Transmission Shaft Assembly
engine oil to the bushings, ball bearings and shafts. • Apply Install the ball bearings on the shafts with the groove to• ward the clutch side. Install the • [B] aligned.gear bushings [A] on the shaft with their holes
CRANKSHAFT/TRANSMISSION 9-29 Transmission any circlips removed with new ones. • Replace Install the [A] so that the opening [B] is aligned • with a splinecirclips groove [C].
drive shaft gears can be recognized by size: the gear • The with the smallest diameter is 1st gear, and the largest one
• • • •
is 6th gear. Be sure that all parts are put back in the correct sequence and all circlips and washers are properly in place. Install the 6th gear bushing onto the drive shaft with their oil holes aligned. The output shaft gears can be recognized by size: the gear with the largest diameter is 1st gear, and the smallest one is 6th gear. Be sure that all parts are put back in the correct sequence and all circlips and washers are properly in place. Install the 5th and 6th gears onto the output shaft with their oil holes aligned. Install the 2nd and 3rd/4th gear bushings onto the output shaft with their oil holes aligned.
the steel balls into the 5th gear holes in the output • Fit shaft, aligning three oil holes [A]. 5th Gear [B] Output Shaft [C] Steel Balls [D]
CAUTION Do not apply grease to the balls to hold them in place. This will cause the positive neutral finder mechanism to malfunction.
○After assembling the 5th gear with steel balls in place on
•
the output shaft, check the ball-locking effect that the 5th gear doesn’t come out of the output shaft when moving it up and down by hand. Check that each gear spins or slides freely on the transmission shafts without binding after assembly.
9-30 CRANKSHAFT/TRANSMISSION Transmission
1. Circlip, 29 mm (1.14 in.) 2. Circlip 3. Thrust Washer, 30 mm (1.18 in.) (Inside Diameter: 25.3 mm (0.996 in.)) 4. Toothed Washer, 30 mm (1.18 in.) 5. Thrust Washer, 30 mm (1.18 in.) (Inside Diameter: 20.5 mm (0.807 in.)) 6. Needle Bearing 7. Bearing Outer Race 8. 2nd Gear 9. Bushing 10. 6th (Top) Gear 11. 3rd Gear 12. 4th Gear 13. 5th Gear 14. 1st Gear
15. Ball Bearing 16. Drive Shaft 17. Nut 18. Washer 19. Collar 20. Oil Seal 21. Bushing 22. 2nd Gear 23. 6th (Top) Gear 24. 3rd Gear 25. Bushing 26. 4th Gear 27. 5th Gear 28. 1st Gear 29. Output Shaft
CRANKSHAFT/TRANSMISSION 9-31 Transmission Shift Drum and Fork Removal
• Remove: Lower Crankcase Half (see Crankcase Splitting) Transmission Shafts (see Transmission Shaft Removal) Shift Drum Positioning Bolt [A] Washer [B] Spring [C] Pin [D]
• Remove: Shift Drum Bearing Holder Bolts [A] Shift Drum Bearing Holder [B] Shift Rods [C] Shift Forks
out the shift drum [A] about half of it, and remove the • Pull circlip [B] and the operating plate [C]. • Pull out the shift drum fully from the upper crankcase.
Shift Drum and Fork Installation
engine oil to the shift drum, forks and rods. • Apply Insert the shift drum into the upper crankcase half, and • install the operating plate pin [A], operating plate [B] and new circlip [C].
NOTE
○When installing the operating plate, the projection [D] of the operating plate faces toward the outside.
the shift rods [E], noting the groove position. •○Install Position the one with shorter ears [F] on the drive shaft and place the pin in the center groove in the shift drum [G]. ○The two forks [H] on the output shaft are identical.
9-32 CRANKSHAFT/TRANSMISSION Transmission the shift drum bearing holder [A]. • Install Apply a non-permanent locking agent to the threads of • the shift drum bearing holder bolts [B], and tighten them. Torque - Shift Drum Bearing Holder Bolts: 12 N·m (1.2 kgf·m, 106 in·lb)
the pin, spring, washer and, tighten the shift drum • Install positioning bolt to the upper crankcase. Torque - Shift Drum Positioning Bolt: 24.5 N·m (2.5 kgf·m, 18 ft·lb)
Shift Drum Disassembly
the shift drum (see Shift Drum and Fork Re• Remove moval). holding the shift drum with a vise, remove the shift • While drum pin plate bolt.
Shift Drum Assembly
sure to install the dowel pin [A]. • Be The drum pins [B] are identical. • Applyshift a non-permanent locking agent to the threads of • the shift drum pin plate bolt [C], and tighten it. Torque - Shift Drum Pin Plate Bolt: 9.0 N·m (0.92 kgf·m, 80 in·lb)
Shift Drum Pin Plate [D] Shift Drum Pin Holder [E] Shift Drum Bearing [F] Shift Drum [G] Operating Plate Pin [H] Operating Plate [I] Circlip [J]
Shift Fork Bending Inspection
inspect the shift forks, and replace any fork that is • Visually bent. A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear when under power. 90° [A]
CRANKSHAFT/TRANSMISSION 9-33 Transmission Shift Fork/Gear Groove Wear Inspection
the thickness of the shift fork ears [A], and mea• Measure sure the width [B] of the gear grooves. If the thickness of a shift fork ear is less than the service limit, the shift fork must be replaced. Shift Fork Ear Thickness Standard: 4.9 ∼ 5.0 mm (0.193 ∼ 0.197 in.) Service Limit: 4.8 mm (0.189 in.)
If the gear groove is worn over the service limit, the gear must be replaced. Gear Groove Width Standard: 5.05 ∼ 5.15 mm (0.199 ∼ 0.203 in.) Service Limit: 5.3 mm (0.209 in.)
Shift Fork Guide Pin/Drum Groove Wear Inspection
the diameter of each shift fork guide pin [A], and • Measure measure the width [B] of each shift drum groove. If the guide pin on any shift fork is less than the service limit, the fork must be replaced. Shift Fork Guide Pin Diameter Standard: 5.9 ∼ 6.0 mm (0.232 ∼ 0.236 in.) Service Limit: 5.8 mm (0.228 in.)
If any shift drum groove is worn over the service limit, the drum must be replaced. Shift Drum Groove Width Standard: 6.05 ∼ 6.20 mm (0.238 ∼ 0.244 in.) Service Limit: 6.3 mm (0.248 in.)
Gear Dog and Gear Dog Hole Damage Inspection
inspect the gear dogs [A] and gear dog holes [B]. • Visually Replace any damaged gears or gears with excessively worn dogs or dog holes.
WHEELS/TIRES 10-1
Wheels/Tires Table of Contents Exploded View........................................................................................................................ Specifications ......................................................................................................................... Special Tools ......................................................................................................................... Wheels (Rims) ........................................................................................................................ Front Wheel Removal ....................................................................................................... Front Wheel Installation .................................................................................................... Rear Wheel Removal........................................................................................................ Rear Wheel Installation..................................................................................................... Wheel Inspection .............................................................................................................. Axle Inspection.................................................................................................................. Balance Inspection............................................................................................................ Balance Adjustment .......................................................................................................... Balance Weight Removal.................................................................................................. Balance Weight Installation............................................................................................... Tires........................................................................................................................................ Air Pressure Inspection/Adjustment.................................................................................. Tire Inspection .................................................................................................................. Tire Removal..................................................................................................................... Tire Installation.................................................................................................................. Tire Repair ........................................................................................................................ Hub Bearing............................................................................................................................ Hub Bearing Removal....................................................................................................... Hub Bearing Installation.................................................................................................... Hub Bearing Inspection..................................................................................................... Hub Bearing Lubrication ................................................................................................... Speedometer Gear Housing................................................................................................... Speedometer Gear Housing Disassembly........................................................................ Speedometer Gear Housing Assembly............................................................................. Speedometer Gear Housing Lubrication...........................................................................
10-2 10-4 10-5 10-6 10-6 10-6 10-8 10-8 10-10 10-10 10-11 10-11 10-11 10-11 10-13 10-13 10-13 10-13 10-14 10-16 10-17 10-17 10-17 10-18 10-18 10-19 10-19 10-19 10-20
10
10-2 WHEELS/TIRES Exploded View
WHEELS/TIRES 10-3 Exploded View No. 1 2
Fastener Front Axle Nut Rear Axle Nut
HG: Apply high-temperature grease. R: Replacement Parts WL: Apply soap and water solution or rubber lubricant.
N·m 88 98
Torque kgf·m 9.0 10.0
ft·lb 65 72.3
Remarks
10-4 WHEELS/TIRES Specifications Item Wheels (Rims) Rim Runout: Axial Radial Axle Runout/100 mm (3.94 in.) Wheel Balance Balance Weights Rim Size: Front Rear Tires Air Pressure (when Cold): Front Rear Tread Depth: Front: IRC BRIDGESTONE DUNLOP Rear: IRC BRIDGESTONE DUNLOP Standard Tires: Front
Rear
Standard
TIR 0.5 mm (0.02 in.) or less TIR 0.8 mm (0.03 in.) or less TIR 0.1 mm (0.004 in.) or less 10 g (0.35 oz.) or less 10 g (0.35 oz.), 20 g (0.71 oz.), 30 g (1.06 oz.) 17 × 2.75 17 × 3.50
Service Limit
TIR 1.0 mm (0.04 in.) TIR 1.0 mm (0.04 in.) TIR 0.2 mm (0.008 in.) – – – – – –
– – – – – –
Up to 170 kg (375 lb) load: 200 kPa (2.00 kgf/cm², 28 psi) Up to 170 kg (375 lb) load: 225 kPa (2.25 kgf/cm², 32 psi)
– – – – – –
4.2 mm (0.17 in.) 4.6 mm (0.18 in.) 4.5 mm (0.18 in.)
1 mm (0.04 in.), (AT, CH, DE) 1.6 mm (0.06 in.)
6.5 mm (0.26 in.) 7.0 mm (0.28 in.) 7.4 mm (0.29 in.)
Up to 130 km/h (80 mph): 2 mm (0.08 in.), Over 130 km/h (80 mph): 3 mm (0.12 in.) Size 110/70 17 M/C (54S) 110/70 17 M/C (54H)
Make, Type IRC RX-01F BRIDGESTONE BATTLAX BT45F DUNLOP GT501F IRC RX-01R BRIDGESTONE BATTLAX BT45R DUNLOP GT501
WARNING Use the same manufacturer’s tires on both front and rear wheels.
130/70 17 M/C (62S) 130/70 17 M/C (62H)
WHEELS/TIRES 10-5 Special Tools Inside Circlip Pliers: 57001-143
Jack: 57001-1238
Rim Protector: 57001-1063
Bearing Remover Shaft, 57001-1265
9:
Bead Breaker Assembly: 57001-1072
Bearing Remover Head, 57001-1267
15 ×
Bearing Driver Set: 57001-1129
Jack Attachment: 57001-1608
17:
10-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal
• Remove: Speedometer Cable Lower End [A] Cotter Pin [B] Axle Nut [C] and Washer Front Caliper Mounting Bolts [D] Front Caliper [E]
the lower fairings (see Lower Fairing Removal in • Remove the Frame chapter). • Raise the front wheel off the ground with the jack. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608
out the axle to the left and drop the front wheel out of • Pull the forks.
CAUTION Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground.
Front Wheel Installation
high-temperature grease to the grease seal lips. • Apply Fit the collar on the right of the hub. • Fit the speedometer • projections [B]. gear projections [A] to the wheel hub
WHEELS/TIRES 10-7 Wheels (Rims) the front wheel so that the speedometer gear hous• Install ing stop [A] fit into the fork leg projection [B].
the front axle, and install the washer. • Insert Tighten: •
Torque - Front Axle Nut: 88 N·m (9.0 kgf·m, 65 ft·lb)
• Insert a new cotter pin [A].
NOTE
○When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [B] up to next alignment. ○It should be within 30°. ○Loosen once and tighten again when the slot goes past the nearest hole.
• Bend the cotter pin [A] over the nut. WARNING
If the rear axle nut is not securely tightened or the cotter pin is not installed, an unsafe riding condition may result.
the speedometer cable so that the drive notch [A] • Install of it fits into the projection [B] of the speedometer pinion in the housing.
the removed parts (see appropriate chapters). • Install the front brake effectiveness (see Brake Operation • Check Inspection in the Periodic Maintenance chapter).
WARNING Do not attempt to drive the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc. The brake will not function on the first application of the lever if this is not done.
10-8 WHEELS/TIRES Wheels (Rims) Rear Wheel Removal
• Raise the rear wheel off the ground with the stand [A].
• Remove: Rear Caliper Mounting Bolts [A] Rear Caliper [B]
• Remove: Cotter Pin [A] Axle Nut [B] Washer [C] Axle [D] (from Left Side)
the drive chain [A] from the rear sprocket toward • Remove the left. • Move the rear wheel back and remove it.
CAUTION
Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground.
Rear Wheel Installation
high-temperature grease to the grease seal lips. • Apply Fit the collars on the both sides of the hub. • Left Side Collar [A] Right Side Collar [B] (with Flange)
WHEELS/TIRES 10-9 Wheels (Rims) the drive chain with the rear sprocket. • Engage Install the caliper bracket [A] onto the swingarm stop [B]. • Insert the axle • the axle nut. from the left side of the wheel, and tighten Torque - Rear Axle Nut: 98 N·m (10.0 kgf·m, 72.3 ft·lb)
• Insert a new cotter pin [A].
NOTE
○When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the axle, tighten the nut clockwise [B] up to next alignment. ○It should be within 30°. ○Loosen once and tighten again when the slot goes past the nearest hole.
• Bend the cotter pin [A] over the nut. WARNING
If the rear axle nut is not securely tightened or the cotter pin is not installed, an unsafe riding condition may result.
the drive chain slack after installation (see Drive • Adjust Chain Slack Inspection in the Periodic Maintenance chap-
• •
ter). Install the rear caliper (see Caliper Installation in the Brakes chapter). Check the rear brake effectiveness (see Brake Operation Inspection in the Periodic Maintenance chapter).
WARNING Do not attempt to drive the motorcycle until a full brake pedal is obtained by pumping the brake pedal until the pads are against the disc. The brake will not function on the first application of the pedal if this is not done.
10-10 WHEELS/TIRES Wheels (Rims) Wheel Inspection
• Raise the front/rear wheel off the ground.
Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608
the wheel lightly, and check for roughness or binding. • Spin If roughness or binding is found, replace the hub bearings
• • •
(see Hub Bearing Removal/Installation). Inspect the wheel for small cracks, dents, bending, or warp. If there is any damage to the wheel, replace the wheel. Remove the wheel, and support it with the tire by the axle. Measure the rim runout, axial [A] and radial [B], with a dial gauge. If rim runout exceeds the service limit, check the hub bearings (see Hub Bearing Inspection). If the problem is not due to the bearings, replace the wheel. Rim Runout (with tire installed) Standard: Axial
TIR 0.5 mm (0.02 in.) or less
Radial
TIR 0.8 mm (0.03 in.) or less
Service Limit: Axial
TIR 1.0 mm (0.04 in.)
Radial
TIR 1.0 mm (0.04 in.)
WARNING Never attempt to repair a damaged wheel. If there is any damage besides wheel bearings, the wheel must be replaced to insure safe operational condition.
Axle Inspection
the front and rear axles (see Front/Rear Wheel • Remove Removal). inspect the front and rear axle for damages. • Visually If the axle is damaged or bent, replace it. the axle in V blocks that are 100 mm (3.94 in.) [A] • Place apart, and set a dial gauge [B] on the axle at a point halfway between the blocks. Turn [C] the axle to measure the runout. The difference between the highest and lowest dial readings is the amount of runout. If axle runout exceeds the service limit, replace the axle. Axle Runout/100 mm (3.94 in.) Standard: TIR 0.1 mm (0.004 in.) or less Service Limit:
TIR 0.2 mm (0.008 in.)
WHEELS/TIRES 10-11 Wheels (Rims) Balance Inspection
the front and rear wheels (see Front/Rear Wheel • Remove Removal). the wheel so that it can be spun freely. • Support Spin the lightly, and mark [A] the wheel at the top • when thewheel wheel stops.
○Repeat this procedure several times.
If the wheel stops of its own accord in various positions, it is well balanced. If the wheel always stops in one position, adjust the wheel balance (see Balance Adjustment).
Balance Adjustment
the wheel always stops in one position, provisionally • Ifattach a balance weight [A] on the rim at the marking using
•
• • •
adhesive tape. Rotate the wheel 1/4 turn [B], and see whether or not the wheel stops in this position. If it does, the correct balance weight is being used. If the wheel rotates and the weight goes up, replace the weight with the next heavier size. If the wheel rotates and the weight goes down, replace the weight with the next lighter size. Repeat these steps until the wheel remains at rest after being rotated 1/4 turn. Rotate the wheel another 1/4 turn and then another 1/4 turn to see if the wheel is correctly balanced. Repeat the entire procedure as many times as necessary to achieve correct wheel balance. Permanently install the balance weight.
Balance Weight Removal
a regular tip screwdrivers [A] [B] between the rib [C] • Insert and the weight [D] as shown in the figure. the balance weight with two screwdrivers and remove • Pry the balance weight. • Discard the used balance weight.
CAUTION
Do not tap the screwdrivers. The rim could be damaged.
Balance Weight Installation
if the weight portion has any play on the blade [A] • Check and clip [B]. If it does, discard it.
WARNING If the balance weight has any play on the rib of the rim, the blade and/or clip have been stretched. Replace the loose balance weight. Do not reuse used balance weight. Unbalanced wheels can create an unsafe riding condition.
10-12 WHEELS/TIRES Wheels (Rims) Balance Weight Part Number
Weight
41075-0007
10 g (0.35 oz.)
41075-0008
20 g (0.71 oz.)
41075-0009
30 g (1.06 oz.)
NOTE
○Balance weights are available from Kawasaki dealers in
10, 20, and 30 grams (0.35, 0.71, and 1.06 oz.) sizes. An imbalance of less than 10 grams (0.35 oz.) will not usually affect running stability. ○Do not use four or more balance weight (more than 90 gram, 3.17 oz.). If the wheel requires an excess balance weight, disassemble the wheel to find the cause. the balance weight [A] onto the rib [B] by pushing or • Slip lightly hammering [C] the clip [D]. Left Side [E] Right Side [F]
sure to install the balance weight. •○Be Check that the blade [A] and clip [B] are fully seated on the rim [C] and that the clip is hooked over the rib [D]. Left Side [E] Right Side [F]
WHEELS/TIRES 10-13 Tires Air Pressure Inspection/Adjustment
to the Air Pressure Inspection in the Periodic Main• Refer tenance chapter.
Tire Inspection
to the Wheel/Tire Damage Inspection in the Peri• Refer odic Maintenance chapter.
Tire Removal
• Remove: Wheels (see Front/Rear Wheel Removal) •
Valve Core (Let out the air) To maintain wheel balance, mark the valve stem position on the tire with chalk so that the tire can be reinstalled in the same position. Chalk Mark or Yellow Mark [A] Air Valve [B] Align [C]
the tire beads and rim flanges on both sides with • Lubricate a soap and water solution or rubber lubricant. This helps the tire beads slip off the rim flanges.
CAUTION Never lubricate with engine oil or petroleum distillates because they will deteriorate the tire. the beads away from both sides of the rim with the • Break bead breaker [A]. Special Tool - Bead Breaker Assembly: 57001-1072
on the side of the tire opposite the valve stem and • Step start prying the tire off the rim near the air valve with tire irons [A]. Special Tools - Rim Protector [B]: 57001-1063 Bead Breaker Assembly: 57001-1072
10-14 WHEELS/TIRES Tires NOTE
○For easier removal, always position the tire bead oppo-
site the valve stem in the rim well, and pry the tire bead a little at a time.
CAUTION Be careful not to scratch the inner liner [A] and air sealing surfaces [B] of the rim and tire with the tire irons. A scratched inner liner or sealing surface may allow air to leak. removing the bead on one side, remove the other • After bead from the same manner. • Remove the tire from the rim.
Tire Installation
WARNING Use the same manufacturer’s tires on both front and rear wheels. the rim and tire, and replace them if necessary. • Inspect Clean the surfaces of the rim and tire, and smooth • the sealingsealing surfaces of the rim with a fine emery cloth if
•
necessary. Remove the air valve and discard it.
CAUTION Replace the air valve whenever the tire is replaced. Do not reuse the air valve.
a new valve in the rim. •○Install Remove the valve cap, lubricate the stem seal [A] with a
soap and water solution or rubber lubricant, and pull [B] the valve stem through the rim from the inside out until it snaps into place.
CAUTION Do not use engine oil or petroleum distillates to lubricate the stem because they will deteriorate the rubber.
○The air valve is shown in the figure. Valve Cap [A] Valve Core [B] Stem Seal [C] Valve Stem [D] Valve Seat [E] Valve Opened [F]
WHEELS/TIRES 10-15 Tires the tire rotation mark on the front and rear tires and • Check install them on the rim accordingly. Tire Rotation Mark [A] Rotating Direction [B]
the tire on the rim so that the air valve [A] align • Position with the tire balance mark [B] (the chalk mark made during removal, or the yellow paint mark on a new tire).
hand, slide as much as possible of the lower side of the • By tire bead over the rim flange, starting at the side opposite
•
the valve stem. Fit the rim protectors and tire irons to install the remaining part of the tire bead which cannot be installed by hand. For easy tire installation, position the parts of the bead which is already over the rim flange in the rim well.
NOTE
○To prevent rim damage, be sure to place the rim protectors at any place the tire irons are applied.
the other side of the tire bead onto the rim in the • Install same manner. the tire beads and rim flanges with a soap and • Lubricate water solution or rubber lubricant to help seat the tire
•
beads in the sealing surfaces of the rim while inflating the tire. Center the rim in the tire beads, and inflate the tire with compressed air until the tire beads seat in the sealing surfaces.
WARNING Be sure to install the valve core whenever inflating the tire, and do not inflate the tire to more than 400 kPa (4.0 kgf/cm², 57 psi). Overinflation can explode the tire with possibility of injury and loss of life.
10-16 WHEELS/TIRES Tires to see that the rim lines [A] on both sides of the tire • Check sidewalls are parallel with the rim flanges. If the rim flanges and tire sidewall rim lines are not parallel, remove the valve core. Lubricate the rim flanges and tire beads. Install the valve core and inflate the tire again. After the tire beads seat in the rim flanges, check for air leakage. ○Inflate the tire slightly above standard inflation. ○Use a soap and water solution or submerge the tire, and check for bubbles that would indicate leakage. Adjust the air pressure to the specified pressure (see Air Pressure Inspection in the Periodic Maintenance chapter). Install the air valve cap. Adjust the wheel balance (see Balance Adjustment).
• • • • • •
Tire Repair Currently two types of repair for tubeless tires have come into wide use. One type is called a temporary (external) repair which can be carried out without removing the tire from the rim, and the other type is called permanent (internal) repair which requires tire removal. It is generally understood that higher running durability is obtained by permanent (internal) repairs than by temporary (external) ones. Also, permanent (internal) repairs have the advantage of permitting a thorough examination for secondary damage not visible from external inspection of the tire. For these reasons, Kawasaki does not recommend temporary (external) repair. Only appropriate permanent (internal) repairs are recommended. Repair methods may vary slightly from make to make. Follow the repair methods indicated by the manufacturer of the repair tools and materials so that safe results can be obtained.
WHEELS/TIRES 10-17 Hub Bearing Hub Bearing Removal
the wheels (see Front/Rear Wheel Removal), • Remove and take out the following. Collars Speedometer Gear (Out of front hub) Coupling (Out of rear hub) Grease Seals Circlips [A] Special Tool - Inside Circlip Pliers: 57001-143
• Use the bearing remover to remove the hub bearings [A]. CAUTION
Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground. Special Tools - Bearing Remover Shaft, 9 [B]: 57001-1265 Bearing Remover Head, 15 × 17 [C]: 57001-1267
Hub Bearing Installation
installing the hub bearings, blow any dirt or foreign • Before particles out of the hub with compressed air to prevent
• •
contamination of the bearings. Replace the bearings with new ones. Install the bearings by using the bearing driver set which does not contact the bearing inner race.
NOTE
○Install the bearings so that the marked side faces out.
• Press in each bearing [A] right until they are bottomed. Special Tool - Bearing Driver Set [B]: 57001-1129
• Replace the circlips with new ones.
Special Tool - Inside Circlip Pliers: 57001-143
the grease seals with new ones. • Replace in the grease seals [A] so that the seal surface is • Press flush [B] with the end of the hole.
○Apply high-temperature grease to the grease seal lips. Special Tool - Bearing Driver Set [C]: 57001-1129
10-18 WHEELS/TIRES Hub Bearing Hub Bearing Inspection Since the hub bearings are made to extremely close tolerances, the clearance can not normally be measured.
NOTE
○Do not remove any bearings for inspection. If any bearings are removed, they will need to be replaced with new ones.
each bearing in the hub back and forth [A] while • Turn checking for plays, roughness, or binding.
•
If bearing play, roughness, or binding is found, replace the bearing. Examine the bearing seal [B] for tears or leakage. If the seal is torn or is leaking, replace the bearing.
Hub Bearing Lubrication NOTE
○Since the hub bearings are packed with grease and sealed, lubrication is not required.
WHEELS/TIRES 10-19 Speedometer Gear Housing Speedometer Gear Housing Disassembly
the speedometer gear housing [A] off the front wheel. • Pull Remove the grease seal [B] and snap ring [C]. • Pull out the speedometer gear [D]. • If the speedometer cable bushing [E] or speedometer pin• ion [F] needs to be removed, work in accordance with following procedures.
drill the housing [A] through the pin [B] using a 1.0 ∼ • First 1.5 mm (0.04 ∼ 0.06 in.) drill bit [C].
the housing from the outside to the pin end [A] using • Drill a 3.0 ∼ 3.5 mm (0.12 ∼ 0.14 in.) drill bit [B].
a 3 mm (0.12 in.) rod [A], tap out the pin [B], • Using and then pull out the speedometer cable bushing and speedometer pinion.
NOTE
○It is recommended that the assembly be replaced rather than attempting to repair the components.
Speedometer Gear Housing Assembly
assembling the speedometer gear housing, • When careful of the following items.
be
○After inserting a new pin, stake the housing hole to secure
the pin in place. ○Apply high-temperature grease to the speedometer gear. ○Replace the grease seal with a new one. Apply a little high -temperature grease to the seal. Install it using a press or a suitable driver so that the face of the seal is level with the surface of the housing.
10-20 WHEELS/TIRES Speedometer Gear Housing Speedometer Gear Housing Lubrication
• Clean and grease [A] the speedometer gear housing [B].
FINAL DRIVE 11-1
Final Drive Table of Contents Exploded View........................................................................................................................ Specifications ......................................................................................................................... Special Tool and Sealant ........................................................................................................ Drive Chain............................................................................................................................. Drive Chain Slack Inspection ............................................................................................ Drive Chain Slack Adjustment .......................................................................................... Wheel Alignment Inspection/Adjustment .......................................................................... Drive Chain Wear Inspection ............................................................................................ Drive Chain Lubrication..................................................................................................... Drive Chain Guide Wear Inspection.................................................................................. Drive Chain Removal ........................................................................................................ Drive Chain Installation ..................................................................................................... Drive Chain Replacement ................................................................................................. Sprocket, Coupling ................................................................................................................. Engine Sprocket Removal ................................................................................................ Engine Sprocket Installation ............................................................................................. Rear Sprocket Removal.................................................................................................... Rear Sprocket Installation................................................................................................. Coupling Installation.......................................................................................................... Coupling Bearing Removal ............................................................................................... Coupling Bearing Installation ............................................................................................ Coupling Bearing Inspection ............................................................................................. Coupling Bearing Lubrication............................................................................................ Coupling Damper Inspection............................................................................................. Sprocket Wear Inspection................................................................................................. Rear Sprocket Warp Inspection ........................................................................................
11-2 11-4 11-5 11-6 11-6 11-6 11-6 11-6 11-6 11-6 11-6 11-6 11-7 11-10 11-10 11-10 11-11 11-11 11-11 11-12 11-12 11-12 11-13 11-13 11-13 11-13
11
11-2 FINAL DRIVE Exploded View
FINAL DRIVE 11-3 Exploded View No. 1 2 3 4 5
Fastener Engine Sprocket Cover Bolts Engine Sprocket Nut Rear Axle Nut Rear Sprocket Nuts Speed Sensor Mounting Bracket Bolts
N·m 9.8 127 98 59 9.8
Torque kgf·m 1.0 13.0 10.0 6.0 1.0
ft·lb 87 in·lb 93.7 72.3 44 87 in·lb
HG: Apply high-temperature grease. HO: Apply heavy oil. L: Apply a non-permanent locking agent. MO: Apply molybdenum disulfide oil solution. (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1) R: Replacement Parts SS: Apply silicone sealant.
Remarks
MO
L
11-4 FINAL DRIVE Specifications Item Drive Chain Drive Chain Slack Drive Chain Wear (20-link Length) Standard Chain: Make Type Link Sprockets Rear Sprocket Warp
Standard
Service Limit
20 ∼ 30 mm (0.8 ∼ 1.2 in.) 317.5 ∼ 318.2 mm (12.50 ∼ 12.53 in.)
– – – 323 mm (12.7 in.)
ENUMA EK520SR-O2 106 links TIR 0.4 mm (0.016 in.) or less
– – – – – – – – – TIR 0.5 mm (0.020 in.)
FINAL DRIVE 11-5 Special Tool and Sealant Bearing Driver Set: 57001-1129
Kawasaki Bond (Silicone Sealant): 92104-0004
11-6 FINAL DRIVE Drive Chain Drive Chain Slack Inspection
to the Drive Chain Slack Inspection in the Periodic • Refer Maintenance chapter.
Drive Chain Slack Adjustment
to the Drive Chain Slack Adjustment in the Periodic • Refer Maintenance chapter.
Wheel Alignment Inspection/Adjustment
to the Wheel Alignment Inspection in the Periodic • Refer Maintenance chapter.
Drive Chain Wear Inspection
to the Drive Chain Wear Inspection in the Periodic • Refer Maintenance chapter.
Drive Chain Lubrication
to the Drive Chain Lubrication Condition in the Pe• Refer riodic Maintenance chapter.
Drive Chain Guide Wear Inspection
to the Chain Guide Wear Inspection in the Periodic • Refer Maintenance chapter.
Drive Chain Removal
• Remove: Chain Cover Bolts [A] and Chain Cover [B] Engine Sprocket (see Engine Sprocket Removal) Rear Wheel (see Rear Wheel Removal in the Wheels/Tires chapter) Swingarm (see Swingarm Removal in the Suspension chapter)
the drive chain [A] from the output shaft [B], and • Remove take it off the chassis.
Drive Chain Installation
the drive chain to the output shaft. • Install Install: • Swingarm (see Swingarm Installation in the Suspension
•
chapter) Rear Wheel (see Rear Wheel Installation in the Wheels/Tires chapter) Engine Sprocket (see Engine Sprocket Installation) Chain Cover Adjust the drive chain slack after installing the chain (see Drive Chain Slack Adjustment in the Periodic Maintenance chapter).
FINAL DRIVE 11-7 Drive Chain Drive Chain Replacement
• Remove: Chain Cover (see Drive Chain Removal) Engine Sprocket Cover (see Engine Sprocket Removal)
CAUTION For safety, if the drive chain shall be replaced, replace it using a recommended tool. Recommended Tool - Type: EK Joint Tool #50 Brand: ENUMA
Body [A] Handlebar [B] Cutting and Riveting Pin [C] For Cutting [D] For Riveting [E] Plate Holder (A) [F] Plate Holder (B) [G] Gauge [H]
[A] the pin head to make it flat. • Grind • Set the cutting and riveting pin [B] as shown in the figure.
the pin holder until it touches the link pin. • Screw Be sure that the cutting pin hits center of the link pin. •
11-8 FINAL DRIVE Drive Chain the handlebar [A] into the body. • Screw Turn the pin holder with the wrench [B] clockwise to ex• tract the link pin.
the link pin, link plate and grease seals. • Replace Apply grease to the link pins [A] and grease seals [B] [C]. • Engage the drive on the engine and rear sprockets. • Insert the link pinschain in the • Install the grease seals. drive chain ends. • Install the link plate so that the mark [D] faces out. • Push the link plate by hand or plier to fix it. • Be sure to set the grease seals correctly. • the plate holder (A) [A] and plate holder (B) [B] on the • Set body.
the plate holder (A) to the link plate. • Fit Turn the pin holder by hand until the plate holder (B) • touches the other link plate.
the pin holder by a wrench clockwise until two pins • Turn of link come into groove of the plate holder (A). • Take off the plate holder.
FINAL DRIVE 11-9 Drive Chain the plate holder (B) [A] and cutting and riveting pin [B] • Set as shown in the figure.
the pin holder until the riveting pin touches the link • Turn pin.
the wrench clockwise until the tip of riveting pin hits • Turn of the link pin. it. • Rivet • Same work for the other link pin.
staking, check the staked area of the link pin for • After cracks. the outside diameter [A] of the link pin and link • Measure plates width [B]. Link Pin Outside Diameter Standard: 5.3 ∼ 5.7 mm (0.21 ∼ 0.22 in.) Link Plates Outside Width Standard: 17.35 ∼ 17.50 mm (0.683 ∼ 0.689 in.)
• • •
If the reading exceeds the specified length, cut and rejoin the chain again. Check: Movement of the Rollers Adjust the drive chain slack after installing the chain (see Drive Chain Slack Adjustment in the Periodic Maintenance chapter). Install the removed parts (see appropriate chapters).
11-10 FINAL DRIVE Sprocket, Coupling Engine Sprocket Removal
• Remove: Shift Lever [A] (see Shift Pedal Removal in the Crankshaft/Transmission chapter) Engine Sprocket Cover Bolts [B] Engine Sprocket Cover [C]
• Remove the bolts [A].
out the bended washer [A]. • Flatten Remove the engine sprocket nut [B] and washer. •
NOTE
○When loosening the engine sprocket nut, hold the rear brake on.
the rear wheel off the ground with the stand. • Raise Loosen the drive chain (see Drive Chain Slack Adjust• ment in the Periodic Maintenance chapter). the drive chain from the rear sprocket toward the • Remove right. the engine sprocket [A] with drive chain [B] off the • Pull output shaft [C]. • Disengage the drive chain from the engine sprocket.
Engine Sprocket Installation
the sprocket washer and axle cotter pin. • Replace Install the • faces inside.engine sprocket so that protruding side [A] molybdenum disulfide oil solution to the threads • Apply and the seating surface of the engine sprocket nut. • Tighten: Torque - Engine Sprocket Nut: 127 N·m (13.0 kgf·m, 93.7 ft·lb)
NOTE
○Tighten the nut while applying the rear brake.
torquing the engine sprocket nut, bend the one side • After of the washer over the nut.
FINAL DRIVE 11-11 Sprocket, Coupling silicone sealant [A] to the crankcase as shown in • Apply the figure. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004
the speed sensor mounting bracket. • Install Tighten: •
Torque - Speed Sensor Mounting Bracket Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
the speed sensor lead correctly (see Cable, Wire, • Run and Hose Routing section in the Appendix chapter). the engine sprocket cover. • Install Tighten: •
Torque - Engine Sprocket Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
the drive chain slack after installing the engine • Adjust sprocket (see Drive Chain Slack Adjustment in the Pe-
•
riodic Maintenance chapter). Install the removed parts (see appropriate chapters).
Rear Sprocket Removal
the rear wheel (see Rear Wheel Removal in the • Remove Wheels/Tires chapter).
CAUTION Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground.
• Remove: Rear Sprocket Nuts [A] Rear Sprocket [B]
Rear Sprocket Installation
the sprocket facing the tooth number marking [A] • Install outward. • Tighten: Torque - Rear Sprocket Nuts: 59 N·m (6.0 kgf·m, 44 ft·lb)
the rear wheel (see Rear Wheel Installation in the • Install Wheels/Tires chapter).
Coupling Installation
high-temperature grease to the following. • Apply Coupling Grease Seal Lips [A] Coupling Internal Surface [A] Ball Bearing [A]
11-12 FINAL DRIVE Sprocket, Coupling high-temperature grease to the following. • Apply Wheel Flange Portion [A]
•
O-ring [B] Install the collar [C].
Coupling Bearing Removal
• Remove: Coupling
Grease Seal
• Remove the bearing [A] by tapping from the wheel side. Special Tool - Bearing Driver Set [B]: 57001-1129
Coupling Bearing Installation
the bearing with a new one. • Replace Press in the bearing [A] until it is bottomed. •
Special Tool - Bearing Driver Set [B]: 57001-1129
○Pack the bearing with high-temperature grease.
the grease seal with a new one. • Replace Press in the seal so that the seal surface is flush • with the end grease of the hole.
○Apply high-temperature grease to the grease seal lips. Special Tool - Bearing Driver Set: 57001-1129
Coupling Bearing Inspection Since the coupling bearing is made to extremely close tolerances, the clearance can not normally be measured.
NOTE
○It is not necessary to remove the coupling bearing for inspection. If the bearing is removed, it will need to be replaced with a new one.
the bearing in the coupling back and forth [A] while • Turn checking for plays, roughness or binding. If the bearing play, roughness or binding is found, replace the bearing.
FINAL DRIVE 11-13 Sprocket, Coupling Coupling Bearing Lubrication
the bearing with high-temperature grease. Turn the • Pack bearing around by hand a few times to make sure the grease is distributed uniformly inside the bearing.
Coupling Damper Inspection
the rear wheel coupling, and inspect the rubber • Remove dampers [A]. the damper if it appears damaged or deterio• Replace rated.
Sprocket Wear Inspection
inspect the engine and rear sprocket teeth for • Visually wear and damage. If the teeth are worn as illustrated, replace the sprocket, and inspect the drive chain wear (see Drive Chain Wear Inspection in the Periodic Maintenance chapter). Worn Tooth (Engine Sprocket) [A] Worn Tooth (Rear Sprocket) [B] Direction of Rotation [C]
NOTE
○If a sprocket requires replacement, the chain is proba-
bly worn also. When replacing a sprocket, inspect the chain.
Rear Sprocket Warp Inspection
the rear wheel off the ground with the stand so that • Raise it will turn freely. a dial gauge [A] against the rear sprocket [B] near the • Set teeth as shown in the figure, and rotate [C] the rear wheel to measure the sprocket runout (warp). The difference between the highest and lowest dial gauge readings is the amount of runout (warp). If the runout exceeds the service limit, replace the rear sprocket. Rear Sprocket Warp Standard: TIR 0.4 mm (0.016 in.) or less Service Limit: TIR 0.5 mm (0.020 in.)
BRAKES 12-1
Brakes Table of Contents Exploded View ....................................................................................................................... Specifications ........................................................................................................................ Special Tools .......................................................................................................................... Brake Lever, Brake Pedal....................................................................................................... Brake Pedal Position Inspection ...................................................................................... Brake Pedal Position Adjustment ..................................................................................... Brake Pedal Removal ....................................................................................................... Brake Pedal Installation .................................................................................................... Calipers .................................................................................................................................. Front Caliper Removal ...................................................................................................... Rear Caliper Removal....................................................................................................... Caliper Installation ............................................................................................................ Front Caliper Disassembly................................................................................................ Front Caliper Assembly..................................................................................................... Rear Caliper Disassembly ................................................................................................ Rear Caliper Assembly ..................................................................................................... Caliper Fluid Seal Damage Inspection.............................................................................. Caliper Dust Seal Damage Inspection .............................................................................. Caliper Dust Boot and Friction Boot Damage Inspection.................................................. Caliper Piston and Cylinder Damage Inspection .............................................................. Caliper Holder Shaft Wear Inspection............................................................................... Brake Pads ............................................................................................................................. Brake Pad Removal .......................................................................................................... Brake Pad Installation ....................................................................................................... Brake Pad Wear Inspection .............................................................................................. Master Cylinder ...................................................................................................................... Front Master Cylinder Removal ........................................................................................ Front Master Cylinder Installation ..................................................................................... Rear Master Cylinder Removal......................................................................................... Rear Master Cylinder Installation...................................................................................... Front Master Cylinder Disassembly .................................................................................. Rear Master Cylinder Disassembly................................................................................... Master Cylinder Assembly ................................................................................................ Master Cylinder Inspection (Visual Inspection)................................................................. Brake Disc .............................................................................................................................. Brake Disc Removal ......................................................................................................... Brake Disc Installation ...................................................................................................... Brake Disc Wear Inspection.............................................................................................. Brake Disc Warp Inspection.............................................................................................. Brake Fluid ............................................................................................................................. Brake Fluid Level Inspection............................................................................................. Brake Fluid Change .......................................................................................................... Brake Line Bleeding.......................................................................................................... Brake Hose............................................................................................................................. Brake Hose Removal/Installation...................................................................................... Brake Hose Inspection......................................................................................................
12-2 12-6 12-7 12-8 12-8 12-8 12-8 12-8 12-9 12-9 12-9 12-9 12-10 12-10 12-10 12-10 12-10 12-11 12-11 12-12 12-12 12-13 12-13 12-13 12-13 12-14 12-14 12-14 12-14 12-14 12-15 12-15 12-15 12-15 12-16 12-16 12-16 12-16 12-16 12-17 12-17 12-17 12-17 12-20 12-20 12-20
12
12-2 BRAKES Exploded View
BRAKES 12-3 Exploded View No. 1 2 3 4 5 6 7 8 9 10 11
Fastener Bleed Valve Brake Hose Banjo Bolts Brake Lever Pivot Bolt Brake Lever Pivot Bolt Locknut Front Brake Disc Mounting Bolts Front Brake Light Switch Screw Front Brake Pad Pins Front Brake Reservoir Cap Screws Front Caliper Holder Pin Bolt Front Caliper Mounting Bolts Front Master Cylinder Clamp Bolts
B: Apply brake fluid. L: Apply a non-permanent locking agent. R: Replacement Parts S: Follow the specified tightening sequence. Si: Apply silicone grease (ex. PBC grease).
N·m 5.5 25 5.9 5.9 27 1.2 17.2 1.5 17.2 25 8.8
Torque kgf·m 0.56 2.5 0.60 0.60 2.8 0.12 1.8 0.15 1.8 2.5 0.90
ft·lb 49 in·lb 18 52 in·lb 52 in·lb 20 11 in·lb 13 13 in·lb 13 18 78 in·lb
Remarks L Si L
Si S
12-4 BRAKES Exploded View
BRAKES 12-5 Exploded View No. 1 2 3 4 5 6 7 8 9
Fastener Bleed Valve Brake Hose Banjo Bolts Brake Pedal Bolt Rear Brake Disc Mounting Bolts Rear Brake Pad Pins Rear Caliper Holder Pin Bolt Rear Caliper Mounting Bolts Rear Master Cylinder Mounting Bolts Rear Master Cylinder Push Rod Locknut
B: Apply brake fluid. G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts Si: Apply silicone grease (ex. PBC grease).
N·m 5.5 25 8.8 27 17.2 17.2 25 25 17.2
Torque kgf·m 0.56 2.5 0.90 2.8 1.8 1.8 2.5 2.5 1.8
ft·lb 49 in·lb 18 78 in·lb 20 13 13 18 18 13
Remarks L
L Si
12-6 BRAKES Specifications Item Brake Lever, Brake Pedal Brake Lever Position Brake Lever Free Play Pedal Free Play Pedal Position Brake Pads Lining Thickness: Front Rear Brake Discs Thickness: Front Rear Runout Brake Fluid Grade
Standard Non-adjustable Non-adjustable Non-adjustable About 40 mm (1.57 in.) below top of footpeg
4.5 mm (0.18 in.) 4.5 mm (0.18 in.)
4.3 ∼ 4.7 mm (0.17 ∼ 0.19 in.) 4.8 ∼ 5.2 mm (0.19 ∼ 0.20 in.) TIR 0.15 mm (0.006 in.) or less DOT4
Service Limit – – – –
– – – –
– – – –
1 mm (0.04 in.) 1 mm (0.04 in.)
4.0 mm (0.16 in.) 4.5 mm (0.18 in.) TIR 0.3 mm (0.01 in.) – – –
BRAKES 12-7 Special Tools Inside Circlip Pliers: 57001-143
Jack: 57001-1238
Jack Attachment: 57001-1608
12-8 BRAKES Brake Lever, Brake Pedal Brake Pedal Position Inspection
that the brake pedal [A] is in the correct position. • Check Footpeg [B] Pedal Position Standard: About 40 mm (1.57 in.) [C] below top of footpeg
If it is incorrect, adjust the brake pedal position.
Brake Pedal Position Adjustment NOTE
○Usually it is not necessary to adjust the pedal position,
but always adjust it when push rod locknut has been loosened.
the locknut [A] and turn the push rod with the hex • Loosen head [B] to achieve the correct pedal position.
•
If the length [C] shown is 80 ±1 mm (3.15 ±0.04 in.), the pedal position will be within the standard range. Tighten: Torque - Rear Master Cylinder Push Rod Locknut: 17.2 N·m (1.8 kgf·m, 13 ft·lb)
the brake light switch operation (see Brake Light • Check Switch Operation Inspection in the Periodic Maintenance chapter).
Brake Pedal Removal
• Remove: Right Front Footpeg Bracket Bolts [A] •
Cotter Pin [B] Joint Pin [C] Rear Brake Light Switch Spring Return Spring Remove the brake pedal bolt and take out the brake pedal [D].
Brake Pedal Installation
grease to the pivot shaft [A] and install the washer • Apply [B]. • Install: Brake Pedal [C]
•
Washer [D] Tighten: Torque - Brake Pedal Bolt [E]: 8.8 N·m (0.90 kgf·m, 78 in·lb)
• Hook: Rear Brake Light Switch Spring • • •
Return Spring [F] Replace the cotter pin with a new one. Insert the cotter pin and bend the pin ends. Install the right front footpeg bracket, and tighten the bolts. Torque - Front Footpeg Bracket Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
the brake pedal position (see Brake Pedal Position • Check Inspection).
BRAKES 12-9 Calipers Front Caliper Removal
the banjo bolt [A] at the brake hose lower end, • Loosen and tighten it loosely. the caliper mounting bolts [B], and detach the • Unscrew caliper [C] from the disc. the banjo bolt and remove the brake hose [D] • Unscrew from the caliper (see Brake Hose Removal/Installation).
CAUTION Immediately wash away any brake fluid that spills.
NOTE
○If the caliper is to be disassembled after removal and if compressed air is not available, disassemble the caliper before the brake hose is removed (see Front Caliper Disassembly).
Rear Caliper Removal
the banjo bolt [A] at the brake hose lower end, • Loosen and tighten it loosely. the caliper mounting bolts [B], and detach the • Unscrew caliper [C] from the disc. the banjo bolt and remove the brake hose [D] • Unscrew from the caliper (see Brake Hose Removal/Installation).
CAUTION Immediately wash away any brake fluid that spills.
NOTE
○If the caliper is to be disassembled after removal and if compressed air is not available, disassemble the caliper before the brake hose is removed (see Rear Caliper Disassembly).
Caliper Installation
the caliper and brake hose lower end. •○Install Replace the washers on each side of hose fitting with new
•
ones. Tighten:
Torque - Caliper Mounting Bolts: Front: 25 N·m (2.5 kgf·m, 18 ft·lb) Rear: 25 N·m (2.5 kgf·m, 18 ft·lb) Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
the fluid level in the brake reservoirs. • Check the brake line (see Brake Line Bleeding). • Bleed Check brake for good braking power, no brake drag, • and nothe fluid leakage.
WARNING Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal and the pads are against the disc. The brakes will not function on the first application of the lever or pedal if this is not done.
12-10 BRAKES Calipers Front Caliper Disassembly
to the Caliper Rubber Parts Replacement in the Pe• Refer riodic Maintenance chapter.
Front Caliper Assembly
to the Caliper Rubber Parts Replacement in the Pe• Refer riodic Maintenance chapter.
Rear Caliper Disassembly
to the Caliper Rubber Parts Replacement in the Pe• Refer riodic Maintenance chapter.
Rear Caliper Assembly
to the Caliper Rubber Parts Replacement in the Pe• Refer riodic Maintenance chapter.
Caliper Fluid Seal Damage Inspection The fluid seal (piston seal) [A] is placed around the piston to maintain clearance between the pad and the disc. If the seal is in a poor condition, it could lead the pad to wear excessively or the brake to drag, which may cause the temperature of the discs or the brake fluid to increase. Replace the fluid seal if it exhibits any of the conditions listed below. ○Brake fluid leakage around the pad. ○Brakes overheat. ○Considerable difference in inner and outer pad wear. ○Seal and piston are stuck together. If the fluid seal is replaced, replace the dust seal [B] as well. Also, replace all seals every other time the pads are changed.
•
BRAKES 12-11 Calipers Caliper Dust Seal Damage Inspection
that the dust seals [A] are not cracked, worn, • Check swollen, or otherwise damaged. If they show any damage, replace the dust seals with new ones. Pistons [B] Fluid Seals [C]
Caliper Dust Boot and Friction Boot Damage Inspection
that the dust boot [A] and friction boot [B] are not • Check cracked, worn, swollen, or otherwise damaged. If they show any damage, replace it.
12-12 BRAKES Calipers Caliper Piston and Cylinder Damage Inspection
inspect the pistons [A] and cylinder surfaces [B]. • Visually Replace the caliper if the cylinder and piston are badly scores or rusty.
Caliper Holder Shaft Wear Inspection The caliper body must slide smoothly on the caliper holder shafts [A]. If the body does not slide smoothly, one pad will wear more than the other, pad wear will increase, and constant drag on the disc will raise brake and brake fluid temperature. Check to see that the caliper holder shafts are not badly worn or stepped, and that the friction boots [B] are not damaged. If the friction boot is damaged, replace the friction boot. To replace the friction boot, remove the pads and the caliper holder. If the caliper holder shaft is damage, replace the caliper holder.
•
BRAKES 12-13 Brake Pads Brake Pad Removal NOTE
○The procedure to remove the front brake pad is as fol-
lows. Removing the rear brake pad is the same as for the front brake pad.
the pad pins [A]. • Loosen Unscrew the bolts [B]. • Remove the caliper with the hose installed. •
• Remove: Pad Pins Brake Pads [A]
Brake Pad Installation
the caliper pistons in by hand as far as they will go. • Push the pad spring [A] in its correct position. • Install Install the outside pad first, then install the inside pad. • Insert the pad pins. •
the caliper (see Caliper Installation). • Install • Tighten:
Torque - Brake Pad Pins: 17.2 N·m (1.8 kgf·m, 13 ft·lb)
WARNING Do not attempt to drive the motorcycle until a full brake lever is obtained by pumping the brake lever and the pads are against the disc. The brake will not function on the first application of the lever if this is not done.
Brake Pad Wear Inspection
to the Brake Pad Wear Inspection in the Periodic • Refer Maintenance chapter.
12-14 BRAKES Master Cylinder Front Master Cylinder Removal
the banjo bolt [A] to disconnect the brake hose • Remove from the master cylinder (see Brake Hose Removal/In-
• •
stallation). Unscrew the clamp bolts [B], and take off the master cylinder [C] as an assembly with the reservoir, brake lever, and brake switch installed. Disconnect the front brake light switch connector [D].
CAUTION Immediately wash away any brake fluid that spills.
Front Master Cylinder Installation
the front master cylinder to match its mating surface • Set [A] to the punch mark [B] of the handlebar. master cylinder clamp must be installed with the ar• The row mark [C] upward. the upper clamp bolt first, and then the lower • Tighten clamp bolt. Torque - Front Master Cylinder Clamp Bolts: 8.8 N·m (0.90 kgf·m, 78 in·lb)
the washers that are on each side of the hose • Replace fitting with new ones. • Tighten:
Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
the brake line (see Brake Line Bleeding). • Bleed Check brake for good braking power, no brake drag, • and nothe fluid leakage.
Rear Master Cylinder Removal
• Remove: Brake Hose Banjo Bolt [A]
• •
Brake Hose [B] Cotter Pin [C] Joint Pin [D] Bolts [E] Rear Master Cylinder [F] Slide out the clamp [G]. Pull off the reservoir hose lower end, and drain the brake fluid into a container.
Rear Master Cylinder Installation
the cotter pin with a new one. • Replace Replace the washers that are on each side of hose fitting • with new ones. • Tighten:
Torque - Rear Master Cylinder Mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
the brake line (see Brake Line Bleeding). • Bleed Check brake for good braking power, no brake drag, • and nothe fluid leakage.
BRAKES 12-15 Master Cylinder Front Master Cylinder Disassembly
to the Master Cylinder Rubber Parts Replacement • Refer in the Periodic Maintenance chapter.
Rear Master Cylinder Disassembly
to the Master Cylinder Rubber Parts Replacement • Refer in the Periodic Maintenance chapter.
Master Cylinder Assembly
to the Master Cylinder Rubber Parts Replacement • Refer in the Periodic Maintenance chapter.
Master Cylinder Inspection (Visual Inspection)
the master cylinders (see Front/Rear Master • Remove Cylinder Removal). the front and rear master cylinders (see • Disassemble Master Cylinder Rubber Parts Replacement in the Peri-
• •
• • •
odic Maintenance chapter). Check that there are no scratches, rust or pitting on the inner wall [A] of each master cylinder and on the outside of each piston [B]. If a master cylinder or piston shows any damage, replace them. Inspect the primary cup [C] and secondary cup [D]. If a cup is worn, damaged softened (rotted), or swollen, the piston assembly should be replaced to renew the cups. If fluid leakage is noted at the brake lever, the piston assembly should be replaced to renew the cups. Check the dust covers [E] for damage. If they are damaged, replace them. Check the piston return springs [F] for any damage. If the springs are damaged, replace them. Check that relief port [G] and supply port [H] are not plugged. If the relief port becomes plugged, the brake pads will drag on the disc. Blow the ports clean with compressed air. Front Master Cylinder [J] Rear Master Cylinder [K]
12-16 BRAKES Brake Disc Brake Disc Removal
the wheels (see Front/Rear Wheel Removal in • Remove the Wheels/Tires chapter). • Unscrew the mounting bolts, and take off the disc.
Brake Disc Installation
the brake disc on the wheel so that the marked side • Install [A] faces out. a non-permanent locking agent to the threads of the • Apply front and rear brake disc mounting bolts [B], and tighten them. Torque - Brake Disc Mounting Bolts: 27 N·m (2.8 kgf·m, 20 ft·lb)
Brake Disc Wear Inspection
the thickness of each disc [A] at the point where • Measure it has worn the most. If the disc has worn past the service limit, replace it. Measuring Area [B] Brake Discs Thickness Standard: Front
4.3 ∼ 4.7 mm (0.17 ∼ 0.19 in.)
Rear
4.8 ∼ 5.2 mm (0.19 ∼ 0.20 in.)
Service Limit: Front
4.0 mm (0.16 in.)
Rear
4.5 mm (0.18 in.)
Brake Disc Warp Inspection
• Raise the front/rear wheel off the ground.
Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608
○For front disc inspection, turn the handlebar fully to one
•
side. Set up a dial gauge against the disc [A] as shown in the figure and measure disc runout, while turning [B] the wheel by hand. If runout exceeds the service limit, replace the disc. Disc Runout Standard: Service Limit:
TIR 0.15 mm (0.006 in.) or less TIR 0.3 mm (0.01 in.)
BRAKES 12-17 Brake Fluid Brake Fluid Level Inspection
to the Brake Fluid Level Inspection in the Periodic • Refer Maintenance chapter.
Brake Fluid Change
to the Brake Fluid Change in the Periodic Mainte• Refer nance chapter.
Brake Line Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action. Air, however, is easily compressed. When air enters the brake lines, brake lever or pedal movement will be partially used in compressing the air. This will make the lever or pedal feel spongy, and there will be a loss in braking power.
WARNING Be sure to bleed the air from the brake line whenever brake lever or pedal action feels soft or spongy after the brake fluid is changed, or whenever a brake line fitting has been loosened for any reason.
NOTE
○The procedure to bleed the front brake line is as follows.
Bleeding the rear brake line is the same as for the front brake.
the reservoir cap [A] and diaphragm. • Remove Fill the reservoir with fresh brake fluid to the upper level • line in the reservoir. pump the brake lever several times until no air • Slowly bubbles can be seen rising up through the fluid from the holes at the bottom of the reservoir. ○Bleed the air completely from the master cylinder by this operation.
the rubber cap [A] from the bleed valve on the • Remove caliper. a clear plastic hose [B] to the bleed valve, and run • Attach the other end of the hose into a container.
12-18 BRAKES Brake Fluid the brake line and the caliper. •○Bleed Repeat this operation until no more air can be seen com-
ing out into the plastic hose. 1. Pump the brake lever until it becomes hard, and apply the brake and hold it [A]. 2. Quickly open and close [B] the bleed valve while holding the brake applied. 3. Release the brake [C].
NOTE
○The fluid level must be checked often during the bleeding operation and replenished with fresh brake fluid as necessary. If the fluid in the reservoir runs completely out any time during bleeding, the bleeding operation must be done over again from the beginning since air will have entered the line. ○Tap the brake hose lightly from the caliper to the reservoir for more complete bleeding. the clear plastic hose. • Remove Install the • Tighten: diaphragm and reservoir cap. •
Torque - Front Brake Reservoir Cap Screws: 1.5 N·m (0.15 kgf·m, 13 in·lb)
the procedure below to install the rear brake fluid • Follow reservoir cap correctly.
○First, tighten the rear brake fluid reservoir cap [B] clockwise [C] by hand until slight resistance is felt indicating that the cap is seated on the reservoir body, then tighten the cap an additional 1/6 turn [D] while holding the brake fluid reservoir body [A].
a non-permanent locking agent to the threads of • Apply the bleed valve. • Tighten the bleed valve, and install the rubber cap. Torque - Bleed Valve: 5.5 N·m (0.56 kgf·m, 49 in·lb)
the fluid level (see Brake Fluid Level Inspection in • Check the Periodic Maintenance chapter). bleeding is done, check the brake for good braking • After power, no brake drag, and no fluid leakage.
BRAKES 12-19 Brake Fluid WARNING When working with the disc brake, observe the precautions listed below. 1. Never reuse old brake fluid. 2. Do not use fluid from a container that has been left unsealed or that has been open for a long time. 3. Do not mix two types and brands of fluid for use in the brake. This lowers the brake fluid boiling point and could cause the brake to be ineffective. It may also cause the rubber brake parts to deteriorate. 4. Don’t leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid. 5. Don’t change the fluid in the rain or when a strong wind is blowing. 6. Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning of the brake parts. Do not use any other fluid for cleaning these parts. Gasoline, engine oil, or any other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any part will be difficult to wash off completely and will eventually deteriorate the rubber used in the disc brake. 7. When handling the disc pads or disc, be careful that no disc brake fluid or any oil gets on them. Clean off any fluid or oil that inadvertently gets on the pads or disc with a high-flash point solvent. Do not use one which will leave an oily residue. Replace the pads with new ones if they cannot be cleaned satisfactorily. 8. Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely wiped up immediately. 9. If any of the brake line fittings or the bleed valve is opened at any time, the AIR MUST BE BLED FROM THE BRAKE LINE.
12-20 BRAKES Brake Hose Brake Hose Removal/Installation
to the Brake Hose and Pipe Replacement in the • Refer Periodic Maintenance chapter.
Brake Hose Inspection
to the Brake Hose and Pipe Damage and Instal• Refer lation Condition Inspection in the Periodic Maintenance chapter.
SUSPENSION 13-1
Suspension Table of Contents Exploded View........................................................................................................................ Specifications ......................................................................................................................... Special Tools .......................................................................................................................... Front Fork ............................................................................................................................... Front Fork Removal (Each Fork Leg) ............................................................................... Front Fork Installation (Each Fork Leg) ............................................................................ Front Fork Oil Change ...................................................................................................... Front Fork Disassembly .................................................................................................... Front Fork Assembly......................................................................................................... Inner Tube, Outer Tube Inspection ................................................................................... Dust Seal Inspection ......................................................................................................... Spring Tension Inspection................................................................................................. Rear Shock Absorber ............................................................................................................. Spring Preload Adjustment ............................................................................................... Rear Shock Absorber Removal ........................................................................................ Rear Shock Absorber Installation ..................................................................................... Rear Shock Absorber Inspection ...................................................................................... Rear Shock Absorber Scrapping ...................................................................................... Swingarm................................................................................................................................ Swingarm Removal........................................................................................................... Swingarm Installation........................................................................................................ Swingarm Bearing Removal ............................................................................................. Swingarm Bearing Installation .......................................................................................... Swingarm Bearing, Sleeve Inspection .............................................................................. Swingarm Bearing Lubrication .......................................................................................... Tie-Rod, Rocker Arm .............................................................................................................. Tie-Rod Removal .............................................................................................................. Tie-Rod Installation ........................................................................................................... Rocker Arm Removal........................................................................................................ Rocker Arm Installation..................................................................................................... Tie-Rod, Rocker Arm Bushing Inspection ......................................................................... Tie-Rod, Rocker Arm Sleeve Inspection ...........................................................................
13-2 13-6 13-7 13-8 13-8 13-8 13-9 13-10 13-11 13-13 13-13 13-13 13-14 13-14 13-14 13-15 13-15 13-15 13-16 13-16 13-17 13-17 13-17 13-17 13-17 13-18 13-18 13-18 13-18 13-18 13-18 13-19
13
13-2 SUSPENSION Exploded View
SUSPENSION 13-3 Exploded View No. 1 2 3
Fastener Front Fork Bottom Allen Bolts Lower Front Fork Clamp Bolts Upper Front Fork Clamp Bolts
G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts
N·m 20 30 20
Torque kgf·m 2.0 3.1 2.0
ft·lb 15 22 15
Remarks L
13-4 SUSPENSION Exploded View
SUSPENSION 13-5 Exploded View No. 1 2 3 4
Fastener Rear Shock Absorber Nuts Swingarm Pivot Shaft Nut Tie-Rod Nuts Uni-Trak Rocker Arm Nut
G: Apply grease. R: Replacement Parts
N·m 59 98 59 59
Torque kgf·m 6.0 10.0 6.0 6.0
ft·lb 44 72.3 44 44
Remarks
13-6 SUSPENSION Specifications Item Front Fork (Per One Unit) Fork Inner Tube Diameter Air Pressure Rebound Damper Setting Fork Spring Preload Setting Fork Oil: Viscosity Amount
Fork Oil Level Fork Spring Free Length Rear Shock Absorber Rebound Damper Setting Spring Preload Setting Gas Pressure
Standard 37 mm (1.5 in.) Atmospheric pressure (Non-adjustable) Non-adjustable Non-adjustable SHOWA SS08 or equivalent SAE 10W Approx. 310 mL (10.5 US oz.) (when changing oil) 360 ±2.5 mL (12.2 ±0.085 US oz.) (after disassembly and completely dry) 108 ±2 mm (4.25 ±0.08 in.) (fully compressed, without fork spring, below from the top of the inner tube) 420.5 mm (16.56 in.) (Service Limit: 412 mm (16.22 in.)) Non-adjustable 2nd position (Adjustable range: 1st ∼ 5th position) 980 kPa (10 kgf/cm², 142 psi, Non-adjustable)
SUSPENSION 13-7 Special Tools Fork Cylinder Holder Handle: 57001-183
Fork Outer Tube Weight: 57001-1218
Fork Cylinder Holder Adapter: 57001-1057
Front Fork Oil Seal Driver: 57001-1219
Oil Seal & Bearing Remover: 57001-1058
Jack: 57001-1238
Steering Stem Nut Wrench: 57001-1100
Fork Oil Level Gauge: 57001-1290
Bearing Driver Set: 57001-1129
Jack Attachment: 57001-1608
13-8 SUSPENSION Front Fork Front Fork Removal (Each Fork Leg)
• Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Front Fender (see Front Fender Removal in the Frame chapter) Bolts [A] (Both Sides) Bracket [B] Remove the handlebar and remove the fork top plug [A] beforehand if the fork leg is to be disassembled.
NOTE
○To remove the top plug, remove the snap ring [B] pushing down the top plug with the screwdriver.
the upper [A] and lower [B] front fork clamp bolts. • Loosen With a twisting motion, remove the fork leg down and out. •
Front Fork Installation (Each Fork Leg)
the fork leg until the inner tube top hit the handlebar • Insert lightly, that is, the distance between the inner tube top [A]
•
and steering stem head surface [B] is approximate 12 mm (0.47 in.) [C]. Tighten: Torque - Lower Front Fork Clamp Bolts: 30 N·m (3.1 kgf·m, 22 ft·lb) Upper Front Fork Clamp Bolts: 20 N·m (2.0 kgf·m, 15 ft·lb)
• Install the removed parts (see appropriate chapters).
SUSPENSION 13-9 Front Fork Front Fork Oil Change
• Remove: Front Fork (see Front Fork Removal) Snap Ring [A] (see Front Fork Removal) Top Plug [B] with O-ring [C] Collar [D] Fork Spring Seat [E] Fork Spring [F]
[A] the fork [B] upside down to draw out the oil • Compress into the suitable container [C].
the fork tube upright, pour in the type and amount of • Hold fork oil specified. Fork Oil Viscosity: SHOWA SS08 or equivalent SAE 10W Amount (Per Side): When changing oil: Approx. 310 mL (10.5 US oz.) After disassembly and completely dry: 360 ±2.5 mL (12.2 ±0.085 US oz.)
NOTE
○Move the outer tube up and down a few times to remove the air that is trapped in the fork oil in order to stabilize the oil level.
13-10 SUSPENSION Front Fork the outer tube vertically in a vise and compress the • Hold fork completely. until the oil level stabilizes. • Wait the fork oil level gauge [A] to measure the distance • Use between the top of the inner tube to the oil level. Special Tool - Fork Oil Level Gauge: 57001-1290
○Set the oil level gauge stopper [B] so that the distance [C]
from the bottom of the stopper to the lower end of the pipe is the standard oil level distance. ○A correct measurement can not be obtained unless the level gauge pipe is placed in the center of the inner tube. Oil Level (fully compressed, without spring) Standard: 108 ±2 mm (4.25 ±0.08 in.)
○Place the stopper of the level gauge at the top [D] of the
inner tube [E] and pull the handle slowly to draw out the excess oil from fork into the gauge, thus attaining the standard level. If not oil is drawn out, there is not enough oil in the fork. Pour in some more oil and measure again.
• Install: Fork Spring [A] • •
Fork Spring Seat [B] Collar [C] Replace the top plug O-ring and snap ring with new ones. Install: Top Plug Snap Ring Front Fork (see Front Fork Installation)
Front Fork Disassembly
the fork oil (see Front Fork Oil Change). • Drain Hold the fork leg horizontally in a vise [A]. • Stop the cylinder unit [B] from turning by using the special • tools. Special Tools - Fork Cylinder Holder Handle [C]: 57001-183 Fork Cylinder Holder Adapter [D]: 57001 -1057
the Allen bolt [E], then take the bolt and gasket • Unscrew out of the bottom of the outer tube. • Take the cylinder unit out of the inner tube.
SUSPENSION 13-11 Front Fork the following from the top of the outer tube. • Remove Dust Seal [A] Retaining Ring [B]
the fork outer tube weight [A] to separate the inner • Use tube from the outer tube. Holding the inner tube by hand in a vertical position, pull down the outer tube several times to pull out the inner tube. Special Tool - Fork Outer Tube Weight: 57001-1218
• Take out the cylinder base from the outer tube bottom. • Remove the inner guide bushing from the inner tube. Front Fork Assembly
the following parts with a new one. • Replace Inner Guide Bushing [A] Oil Seal [B] Outer Guide Bushing [C] Bottom Allen Bolt Gasket [D]
the cylinder unit [A] with the spring into the inner tube • Put [B] protruding from the inner tube, and install the cylinder base [C] onto the bottom end of the cylinder unit.
○Install the cylinder base with the tapered end [D] facing
•
upward. Install the inner tube, cylinder unit, and cylinder base as a set into the outer tube.
13-12 SUSPENSION Front Fork the new guide bushing [A] with a use one [B] on it • Install by tapping the use one with the fork oil seal driver [C].
○The split [D] of the bushing should face toward the side of the motorcycle.
Special Tool - Front Fork Oil Seal Driver: 57001-1219
molybdenum disulfide grease to the oil seal lips, • Apply and install the washer and the oil seal [A] into the outer tube. Special Tool - Front Fork Oil Seal Driver [B]: 57001-1219
• Install the retaining ring on the outer tube.
a new bottom Allen bolt gasket. • Install Apply a locking agent to the threads of • the bottomnon-permanent Allen bolt, and tighten it. the outer tube in a vise [A], stop the cylinder unit [B] • Hold with the special tools, then tighten the Allen bolt [C]. Special Tools - Fork Cylinder Holder Handle [D]: 57001-183 Fork Cylinder Holder Adapter [E]: 57001 -1057 Torque - Front Fork Bottom Allen Bolts: 20 N·m (2.0 kgf·m, 15 ft·lb)
the dust seal. • Install Pour in • Change).the specified type of oil (see Front Fork Oil
SUSPENSION 13-13 Front Fork Inner Tube, Outer Tube Inspection
inspect the inner tube [A], and repair any dam• Visually age. or rust damage can sometimes be repaired by using • Nicks a wet-stone to remove sharp edges or raised areas which cause seal damage. If the damage is not repairable, replace the inner tube. Since damage to the inner tube damages the oil seal, replace the oil seal whenever the inner tube is repaired or replaced.
CAUTION If the inner tube is badly bent or creased, replace it. Excessive bending, followed by subsequent straightening, can weaken the inner tube. assemble the inner and outer [B] tubes, and • Temporarily pump them back and forth manually to check for smooth operation. If you feel binding or catching, the inner and outer tubes must be replaced.
WARNING A straightened inner or outer fork tube may fail in use, possibly causing an accident. Replace a badly bent or damaged inner or outer tube and inspect the other tube carefully before reusing it.
Dust Seal Inspection
the dust seal [A] for any signs of deterioration or • Inspect damage. Replace it if necessary.
Spring Tension Inspection
a spring becomes shorter as it weakens, check its • Since free length [A] to determine its condition. If the spring of either fork leg is shorter than the service limit, it must be replaced. If the length of a replacement spring and that of the remaining spring vary greatly, the remaining spring should also be replaced in order to keep the fork legs balanced for motorcycle stability. Spring Free Length Standard: 420.5 mm (16.56 in.) Service Limit: 412 mm (16.22 in.)
13-14 SUSPENSION Rear Shock Absorber Spring Preload Adjustment
the bolts [A], chain cover [B] and left front footpeg • Remove bracket [C] for turning the wrench easily.
the steering stem nut wrench [A], turn the adjusting • Using nut to adjust the spring preload. Special Tool - Steering Stem Nut Wrench: 57001-1100
○The standard adjuster setting for average-build rider of 68 kg (150 Ib) with no passenger and no accessories is 2nd position. Spring Preload Setting Standard Position:
2nd position 1st ∼ 5th position
Adjustable Range:
the compression of the spring is not suited to the op• Iferating conditions, adjust it to an appropriate position by referring to the table below. Spring Preload Adjustment Shock Adjuster Damping Absorber Position Force Hardness
Load
Road Conditions
Driving Speed
1st
Weak
Soft
Light
Good
Low
↑
↑
↑
↑
↑
↑
↓
↓
↓
↓
↓
↓
5th
Strong
Hard
Heavy
Bad
Highway
Rear Shock Absorber Removal
the brake lever slowly and hold it with a band • Squeeze [A].
WARNING Be sure to hold the front brake when removing the shock absorber, or the motorcycle may fall over. It could cause an accident and injury. the lower fairings (see Lower Fairing in the • Remove Frame chapter). • Raise the rear wheel off the ground with jack. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608
SUSPENSION 13-15 Rear Shock Absorber
• Remove the caps [A] (both sides).
• Remove: Lower Tie-Rod Nut and Bolt [A] •
Rear Shock Absorber Nuts and Bolts [B] Remove the shock absorber [C] from downside.
Rear Shock Absorber Installation the rear shock absorber. • Install Tighten: •
Torque - Rear Shock Absorber Nuts: 59 N·m (6.0 kgf·m, 44 ft·lb) Tie-Rod Nuts: 59 N·m (6.0 kgf·m, 44 ft·lb)
• Install the removed parts (see appropriate chapters). Rear Shock Absorber Inspection
the rear shock absorber (see Rear Shock Ab• Remove sorber Removal). inspect the following items. • Visually Smooth Stroke
•
Oil Leakage Crack or Dent If there is any damage to the rear shock absorber, replace it. Visually inspect the rubber bushing. If it show any signs of damage, replace it.
Rear Shock Absorber Scrapping
WARNING Since the rear shock absorber contains nitrogen gas, do not incinerate the rear shock absorber without first releasing the gas or it may explode. Before a rear shock absorber is scrapped, drill a hole at the point [A] shown to release the nitrogen gas completely. Wear safety glasses when drilling the hole, as the gas may below out bits of drilled metal when the hole opens. the rear shock absorber (see Rear Shock Ab• Remove sorber Removal). the cylinder of the shock absorber using about 2 mm • Drill (0.08 in.) drillbit.
13-16 SUSPENSION Swingarm Swingarm Removal
• Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Chain Cover (see Drive Chain Removal in the Final Drive chapter) Rear Wheel (see Rear Wheel Removal in the Wheels/Tires chapter) Caps [A] (Both Sides)
• Remove: Bolt [A] Clamp [B]
• Raise the rear wheel off the ground with jack. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608
• Remove: Lower Rear Shock Absorber Nut and Bolt [A] Upper Tie-Rod Nut and Bolt [B]
• Unscrew the swingarm pivot shaft nut [A].
• Pull out the pivot shaft [A] and remove the swingarm [B].
SUSPENSION 13-17 Swingarm Swingarm Installation
is the reverse of removal. •○Installation Apply grease to the lips of the oil seals.
○Tighten:
Torque - Swingarm Pivot Shaft Nut: 98 N·m (10.0 kgf·m, 72.3 ft·lb)
• Install the removed parts (see appropriate chapters). Swingarm Bearing Removal
• Remove: Swingarm (see Swingarm Removal) Oil Seals [A] Sleeve [B]
• Remove the needle bearings.
Special Tool - Oil Seal & Bearing Remover [A]: 57001-1058
Swingarm Bearing Installation
plenty of grease to the needle bearings. • Apply Install the needle bearings so that the manufacturer’s • marks face out. Special Tool - Bearing Driver Set [A]: 57001-1129
Swingarm Bearing, Sleeve Inspection CAUTION Do not remove the bearings for inspection. Removal may damage them. the needle bearings [A] installed in the swingarm. •○Inspect The rollers in a needle bearing normally wear very little,
and wear is difficult to measure. Instead of measuring, visually inspect the bearing for abrasion, discoloration, or other damage. If the needle bearing and sleeve [B] show any signs of abnormal wear, discoloration, or damage, replace them as a set.
Swingarm Bearing Lubrication
to the Swingarm Pivot Lubrication in the Periodic • Refer Maintenance chapter.
13-18 SUSPENSION Tie-Rod, Rocker Arm Tie-Rod Removal
the brake lever slowly and hold it with a band • Squeeze [A].
the lower fairings (see Lower Fairing Removal in • Remove the Frame chapter). • Raise the rear wheel off the ground with the jack. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608
• Remove: Upper Tie-Rod Nut and Bolt [A]
Lower Tie-Rod Nut and Bolt [B] Tie-Rods [C]
Tie-Rod Installation
grease to the inside of the oil seals and O-rings. • Apply Tighten: • Torque - Tie-Rod Nuts: 59 N·m (6.0 kgf·m, 44 ft·lb)
• Install the removed parts (see appropriate chapters). Rocker Arm Removal
the brake lever slowly and hold it with a band. • Squeeze Remove the lower fairings (see Lower Fairing Removal in • the Frame chapter). • Raise the rear wheel off the ground with the jack. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608
• Remove: Lower Rear Shock Absorber Nut and Bolt [A] Lower Tie-Rod Nut and Bolt [B] Rocker Arm Nut and Bolt [C] Rocker Arm [D]
Rocker Arm Installation
grease to the inside of the oil seals and O-rings. • Apply • Tighten:
Torque - Uni-Trak Rocker Arm Nut: 59 N·m (6.0 kgf·m, 44 ft·lb) Tie-Rod Nuts: 59 N·m (6.0 kgf·m, 44 ft·lb) Rear Shock Absorber Nuts: 59 N·m (6.0 kgf·m, 44 ft·lb)
• Install the removed parts (see appropriate chapters). Tie-Rod, Rocker Arm Bushing Inspection
bushings wear so little that the wear is difficult to mea• The sure. Instead, inspect the bushings for abrasion, color change, or other damage. If there is any doubt as to the condition of either bushings, replace the bushing with a new one.
SUSPENSION 13-19 Tie-Rod, Rocker Arm Tie-Rod, Rocker Arm Sleeve Inspection
inspect the sleeves. • Visually If there is visible damage, replace the sleeve with a new one.
STEERING 14-1
Steering Table of Contents Exploded View........................................................................................................................ Special Tools .......................................................................................................................... Steering .................................................................................................................................. Steering Inspection ........................................................................................................... Steering Adjustment.......................................................................................................... Steering Stem......................................................................................................................... Stem, Stem Bearing Removal........................................................................................... Stem, Stem Bearing Installation........................................................................................ Steering Stem Bearing Lubrication ................................................................................... Steering Stem Warp Inspection ........................................................................................ Oil Seal Deterioration, Damage Inspection....................................................................... Handlebar ............................................................................................................................... Handlebar Removal .......................................................................................................... Handlebar Installation .......................................................................................................
14-2 14-4 14-5 14-5 14-5 14-6 14-6 14-7 14-9 14-9 14-9 14-10 14-10 14-10
14
14-2 STEERING Exploded View
STEERING 14-3 Exploded View No. 1 2 3 4 5 6
Fastener Handlebar Mounting Bolts Lower Front Fork Clamp Bolts Steering Stem Head Bolt Steering Stem Nut Switch Housing Screws Upper Front Fork Clamp Bolts
AD: Apply adhesive. G: Apply grease. L: Apply a non-permanent locking agent.
N·m 25 30 44 4.9 3.5 20
Torque kgf·m 2.5 3.1 4.5 0.50 0.36 2.0
ft·lb 18 22 32 43 in·lb 31 in·lb 15
Remarks
14-4 STEERING Special Tools Steering Stem Bearing Driver: 57001-137
Head Pipe Outer Race Press Shaft: 57001-1075
Bearing Puller: 57001-158
Head Pipe Outer Race Driver, 57001-1076
Bearing Puller Adapter: 57001-317
Steering Stem Nut Wrench: 57001-1100
Oil Seal & Bearing Remover: 57001-1058
Head Pipe Outer Race Driver, 57001-1447
Steering Stem Bearing Driver Adapter, 57001-1074
34.5:
51.5:
47:
STEERING 14-5 Steering Steering Inspection
to the Steering Play Inspection in the Periodic Main• Refer tenance chapter.
Steering Adjustment
to the Steering Play Adjustment in the Periodic • Refer Maintenance chapter.
14-6 STEERING Steering Stem Stem, Stem Bearing Removal
• Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Handlebars (see Handlebar Removal) Front Forks (see Front Fork Removal in the Suspension chapter) Steering Stem Head Bolt [A] Steering Stem Head [B]
• Remove the bolts [A].
up the stem base, and remove the steering stem • Pushing nut [A] and stem cap [B]. Special Tool - Steering Stem Nut Wrench [C]: 57001-1100
• Remove: Steering Stem [D]
Upper Ball Bearing Inner Race and Ball Bearings
NOTE
○Be aware of removing the steering stem so that the stem bearing steel balls are not lost.
the upper and lower outer races using the re• Remove mover [A]. Special Tool - Oil Seal & Bearing Remover: 57001-1058
NOTE
○If either steering stem bearing is damaged, it is recommended that both the upper and lower bearings (including outer races) should be replaced with new ones.
STEERING 14-7 Steering Stem the lower ball bearing inner race (with its oil seal) • Remove [A] which is pressed onto the steering stem using the bearing puller [B] and adapter [C]. Special Tools - Bearing Puller: 57001-158 Bearing Puller Adapter: 57001-317
Stem, Stem Bearing Installation
the bearing outer races with new ones. • Replace Drive them into the head pipe at the same time. •
Special Tools - Head Pipe Outer Race Press Shaft [A]: 57001-1075 Head Pipe Outer Race Driver, 51.5 [B]: 57001-1076 Head Pipe Outer Race Driver, 47 [C]: 57001 -1447
• Apply grease to the outer races. the bearing inner races and oil seal with new • Replace ones. grease to the oil seal. • Apply Install the washer [A] and oil seal [B] on the steering stem, • and drive the ball bearing inner race [C] applied grease onto the stem. Special Tools - Steering Stem Bearing Driver [D]: 57001 -137 Steering Stem Bearing Driver Adapter, 34.5 [E]: 57001-1074
grease to the lower ball bearings (20) [A] and inner • Apply race [B], and install the ball bearings onto the inner race.
grease to the upper ball bearings (19) [A] and outer • Apply race [B], and install the ball bearings onto the outer race.
14-8 STEERING Steering Stem the steering stem [A] carefully through the head • Install pipe so that the steel balls on the steering stem does not
•
fall. Install the stem cap [B] and steering stem nut [C], and tighten it by hand.
the stem head [A]. • Install Tighten the stem head bolt [B] lightly. •
the bearings in place as follows. •○Settle Tighten the steering stem nut with 15 N·m (1.5 kgf·m, 11
ft·lb) of torque first, and loosen it a fraction of a turn until it turns lightly (To tighten the stem nut to the specified torque, hook the wrench on the stem nut, and pull the wrench at the hole by 84 N (8.6 kgf, 19 lb) [A] force in the direction shown.). Afterward tighten it again with specified torque using a steering stem nut wrench [B]. Special Tool - Steering Stem Nut Wrench: 57001-1100 Torque - Steering Stem Nut: 4.9 N·m (0.50 kgf·m, 43 in·lb)
the steering (see Steering Play Inspection in the • Adjust Periodic Maintenance chapter). the front forks (see Front Fork Installation in the • Install Suspension chapter).
NOTE
○Tighten the upper front fork clamp bolts first, next the stem head bolt, last the lower front fork clamp bolts.
Torque - Upper Front Fork Clamp Bolts: 20 N·m (2.0 kgf·m, 15 ft·lb) Steering Stem Head Bolt: 44 N·m (4.5 kgf·m, 32 ft·lb) Lower Front Fork Clamp Bolts: 30 N·m (3.1 kgf·m, 22 ft·lb)
WARNING Do not impede the handlebar turning by routing the cables, harnesses and hoses improperly (see Cable, Wire and Hose Routing section in the Appendix chapter).
• Install the removed parts (see appropriate chapters).
STEERING 14-9 Steering Stem Steering Stem Bearing Lubrication
to the Steering Stem Bearing Lubrication in the Pe• Refer riodic Maintenance chapter.
Steering Stem Warp Inspection
the steering stem [A] is removed, or if the • Whenever steering can not be adjusted for smooth action, check the steering stem for straightness. If the steering stem is bent, replace the steering stem.
Oil Seal Deterioration, Damage Inspection
the oil seal for any sign of deterioration or dam• Inspect age. If the oil seal is deterioration or damage, replace it with a new one.
14-10 STEERING Handlebar Handlebar Removal
• Remove: Left Switch Housing [A] Handlebar Weight [B] Left Handlebar Grip [C] Clutch Lever Clamp Bolt [D] Clutch Lever Assembly [E] Bolts [F] Left Handlebar [G]
• Remove: Front Master Cylinder [A] (see Front Master Cylinder Removal in the Brakes chapter) Right Switch Housing [B] Handlebar Weight [C] Throttle Grip [D] Bolts [E] Right Handlebar [F]
Handlebar Installation
• Tighten:
Torque - Handlebar Mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
the clutch lever (see Clutch Lever Installation in the • Install Clutch chapter). adhesive cement to the inside of the left handlebar • Apply grip, and install it. a non-permanent locking agent to the left handlebar • Apply weight screw, and tighten it. the left switch housing. •○Install Fit the projection [A] into a hole [B] in the handlebar. • Tighten:
Torque - Switch Housing Screws: 3.5 N·m (0.36 kgf·m, 31 in·lb)
• Install: Throttle Grip Throttle Cable Tips [A] Right Switch Housing ○Fit the projection [B] into a hole [C] in the handlebar. Tighten:
•
Torque - Switch Housing Screws: 3.5 N·m (0.36 kgf·m, 31 in·lb)
a non-permanent locking agent to the right handle• Apply bar weight screw, and tighten it. the front brake master cylinder (see Front Master • Install Cylinder Installation in the Brakes chapter).
FRAME 15-1
Frame Table of Contents Exploded View........................................................................................................................ Seats ...................................................................................................................................... Rear Seat Removal........................................................................................................... Rear Seat Installation........................................................................................................ Front Seat Removal .......................................................................................................... Front Seat Installation ....................................................................................................... Fairings................................................................................................................................... Lower Fairing Removal ..................................................................................................... Lower Fairing Installation .................................................................................................. Windshield Removal ......................................................................................................... Windshield Installation ...................................................................................................... Upper Fairing Removal ..................................................................................................... Upper Fairing Disassembly............................................................................................... Upper Fairing Assembly.................................................................................................... Upper Fairing Installation .................................................................................................. Inner Cover Removal ........................................................................................................ Inner Cover Installation ..................................................................................................... Upper Fairing Bracket Removal........................................................................................ Upper Fairing Bracket Installation..................................................................................... Inner Fairing Removal....................................................................................................... Inner Fairing Installation.................................................................................................... Side Cover.............................................................................................................................. Side Cover Removal ......................................................................................................... Side Cover Installation ...................................................................................................... Seat Covers............................................................................................................................ Seat Cover Removal......................................................................................................... Seat Cover Installation...................................................................................................... Fenders .................................................................................................................................. Front Fender Removal ...................................................................................................... Front Fender Installation ................................................................................................... Flap and Rear Fender Removal........................................................................................ Flap and Rear Fender Installation..................................................................................... Frame ..................................................................................................................................... Frame Inspection .............................................................................................................. Sidestand................................................................................................................................ Sidestand Removal........................................................................................................... Sidestand Installation........................................................................................................
15-2 15-7 15-7 15-7 15-7 15-7 15-8 15-8 15-8 15-8 15-9 15-9 15-9 15-9 15-9 15-9 15-9 15-10 15-10 15-10 15-10 15-11 15-11 15-11 15-12 15-12 15-12 15-14 15-14 15-14 15-14 15-15 15-16 15-16 15-17 15-17 15-17
15
15-2 FRAME Exploded View
FRAME 15-3 Exploded View No. 1 2 3 4
Fastener Front Footpeg Bracket Bolts Rear Footpeg Bracket Bolts Sidestand Nut Sidestand Switch Bolt
G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts
N·m 25 25 39 8.8
Torque kgf·m 2.5 2.5 4.0 0.90
ft·lb 18 18 29 78 in·lb
Remarks
L
15-4 FRAME Exploded View
FRAME 15-5 Exploded View No. 1
Fastener Windshield Mounting Bolts
N·m 0.42
Torque kgf·m 0.043
ft·lb 3.7 in·lb
Remarks
15-6 FRAME Exploded View
FRAME 15-7 Seats Rear Seat Removal
the ignition switch key [A] into the seat lock, turning • Insert the key clockwise, pulling the front part of the seat [B] up, and pull the seat forward.
Rear Seat Installation
the rear seat slot [A] to the bracket [B] of the frame. • Insert Insert the seat hook [C] into the latch hole [D]. • Push down the front part of the seat until the lock clicks. •
Front Seat Removal
• Remove: Side Covers (see Side Cover Removal) •
Bolts [A] (Both Sides) Pull the front seat [B] backward.
Front Seat Installation
the front seat hooks [A] into the braces [B] of the • Insert bracket. the bolts. • Tighten Install the side covers (see Side Cover Installation). •
15-8 FRAME Fairings Lower Fairing Removal
• Remove: Side Covers (see Side Cover Removal) Rivets [A] Bolts [B] Front Turn Signal Light Lead Connectors (Disconnect) Lower Fairings [C]
Lower Fairing Installation
is the reverse of removal. •○Installation Run the front turn signal light lead [A] to the hooks [B].
○Fit [A] the front portion of the lower fairing in the rear por-
tion of the upper fairing. ○Install the tabs [B] of the lower fairing into the slots [C] of the inner cover.
Windshield Removal
• Remove: Bolts [A] with Washer Windshield [B]
FRAME 15-9 Fairings Windshield Installation
the bottom end [A] to the projection [B]. • Put Tighten: • Torque - Windshield Mounting Bolts: kgf·m, 3.7 in·lb)
0.42 N·m (0.043
Upper Fairing Removal
• Remove: Windshield (see Windshield Removal) •
Lower Fairings (see Lower Fairing Removal) Inner Fairing (see Inner Fairing Removal) Bolts [A] (Both Sides) Pull out the upper fairing [B] forward.
• Disconnect: Headlight Lead Connectors [A] •
City Light Lead Connector [B] Remove the upper fairing [C].
Upper Fairing Disassembly
• Remove: Upper Fairing (see Upper Fairing Removal) Bolts [A] Headlight [B] Brackets [C] Nuts [D] and Rear View Mirrors
Upper Fairing Assembly
• Assembly is the reverse of disassembly. Upper Fairing Installation
• Installation is the reverse of removal. Inner Cover Removal
to the Meter Unit Removal/Installation in the Elec• Refer trical System chapter.
Inner Cover Installation
to the Meter Unit Removal/Installation in the Elec• Refer trical System chapter.
15-10 FRAME Fairings Upper Fairing Bracket Removal
• Remove: Upper Fairing (see Upper Fairing Removal) Meter Unit (see Meter Unit Removal/Installation in the Electrical System chapter) Fuel Tank [A] (see Fuel Tank Removal in the Fuel System (DFI) chapter) Clutch Cable [B] Throttle Cables [C] Left and Right Switch Housing Lead Connectors Ignition Switch Lead Connector Bands [D] Bolt [E] Nuts [F] and Bolts Upper Fairing Bracket [G]
Upper Fairing Bracket Installation
is the reverse of removal. • Installation Run the cables and leads correctly (see Cable, Wire, and • Hose Routing section in the Appendix chapter).
Inner Fairing Removal
• Remove: Lower Fairings (see Lower Fairing Removal) Rivets [A] (Both Sides) Screws [B] (Both Sides) Inner Fairing [C]
Inner Fairing Installation
the front portions [A] of the inner fairing into the lower • Fit portions [B] of the upper fairing.
FRAME 15-11 Side Cover Side Cover Removal
the screw [A]. • Remove Pull the side • pers [C]. cover [B] evenly outward to clear the stop-
Side Cover Installation
the groove [A] to the projection [B]. • Fit Insert [C] into the holes [D]. • Tightenthetheprojections screw. •
15-12 FRAME Seat Covers Seat Cover Removal
• Remove: Side Covers (see Side Cover Removal) •
Seats (see Rear/Front Seat Removal) Bolts [A] Pull the left and right seat covers [B] to clear the stoppers [C].
the projections [A] from the holes [B], and pull • Remove out the center seat cover [C] forward.
Seat Cover Installation
is the reverse of removal. •○Installation Install the damper to the center seat cover so that its flatten side [A] faces downward.
○Put the projection [A] into the hole [B] of the tail/brake light. ○Put the holes [C] to the projections [D] of the rear fender.
○Be sure that the damper [A] is in position.
FRAME 15-13 Seat Covers
○Put the projections [A] into the holes [B].
• Install the removed parts (see appropriate chapters).
15-14 FRAME Fenders Front Fender Removal
• Remove: Bolts [A] with Collar (Both Sides) Front Fender [B]
Front Fender Installation
• Installation is the reverse of removal. Flap and Rear Fender Removal
• Remove: Seat Covers (see Seat Cover Removal) Bolts [A] (Both Sides) Rear Footpeg Brackets [B] (Both Sides)
• Remove: Relay Box [A] (see Relay Box Removal in the Electrical System chapter) Battery Case [B] (see Battery Removal in the Electrical System chapter) ECU [C] (see ECU Removal in the Fuel System (DFI) chapter)
• Remove: Fuse Box [A] Clamp [B] Connectors [C]
FRAME 15-15 Fenders
• Remove: Tail/Brake Light (see Tail/Brake Light Removal in the Electrical System chapter) Owner’s Tool [A] Connector [B] Bolts [C] Flap (with Turn Signal and License Plate Lights)
the screws [A] (both sides). • Remove Pull out the rear fender backward. •
Flap and Rear Fender Installation
is the reverse of removal. • Installation Install the removed parts (see appropriate chapters). •
Torque - Rear Footpeg Bracket Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
the cable, leads and harness correctly (see Cable, • Run Wire, and Hose Routing section in the Appendix chapter).
15-16 FRAME Frame Frame Inspection
inspect the frame for cracks, dents, bending, or • Visually warp. If there is any damage to the frame, replace it.
WARNING A repaired frame may fail in use, possibly causing an accident. If the frame is bent, dented, cracked, or warped, replace it.
FRAME 15-17 Sidestand Sidestand Removal
the rear wheel off the ground with the stand. • Raise Remove: • Sidestand Switch Bolt [A] Sidestand Switch [B] Spring [C] Sidestand Bolt [D] Sidestand [E]
Sidestand Installation
grease to the sliding area [A] of the sidestand [B]. • Apply Tighten the bolt and lock them with the nut. • Torque - Sidestand Nut: 39 N·m (4.0 kgf·m, 29 ft·lb)
the spring [C] so that face the long spring end up• Hook ward.
○Install the spring hook direction as shown in the figure.
the sidestand switch. • Install Apply a locking agent to the threads of • the switchnon-permanent bolt, and tighten it. Torque - Sidestand Switch Bolt: 8.8 N·m (0.90 kgf·m, 78 in·lb)
ELECTRICAL SYSTEM 16-1
Electrical System Table of Contents Exploded View........................................................................................................................ Specifications ......................................................................................................................... Special Tools and Sealant ...................................................................................................... Parts Location......................................................................................................................... Wiring Diagram....................................................................................................................... Precautions............................................................................................................................. Electrical Wiring...................................................................................................................... Wiring Inspection .............................................................................................................. Battery .................................................................................................................................... Battery Removal ............................................................................................................... Battery Installation ............................................................................................................ Battery Activation .............................................................................................................. Precautions ....................................................................................................................... Interchange ....................................................................................................................... Charging Condition Inspection.......................................................................................... Refreshing Charge............................................................................................................ Charging System .................................................................................................................... Alternator Cover Removal................................................................................................. Alternator Cover Installation.............................................................................................. Stator Coil Removal .......................................................................................................... Stator Coil Installation ....................................................................................................... Alternator Rotor Removal ................................................................................................. Alternator Rotor Installation .............................................................................................. Charging Voltage Inspection ............................................................................................. Alternator Inspection ......................................................................................................... Regulator/Rectifier Inspection........................................................................................... Ignition System ....................................................................................................................... Crankshaft Sensor Removal ............................................................................................. Crankshaft Sensor Installation .......................................................................................... Crankshaft Sensor Inspection........................................................................................... Crankshaft Sensor Peak Voltage Inspection..................................................................... Stick Coil Removal............................................................................................................ Stick Coil Installation......................................................................................................... Stick Coil Inspection.......................................................................................................... Stick Coil Primary Peak Voltage ....................................................................................... Spark Plug Removal ......................................................................................................... Spark Plug Installation ...................................................................................................... Spark Plug Condition Inspection....................................................................................... Interlock Operation Inspection .......................................................................................... IC Igniter Inspection .......................................................................................................... Electric Starter System ........................................................................................................... Starter Motor Removal...................................................................................................... Starter Motor Installation................................................................................................... Starter Motor Disassembly................................................................................................ Starter Motor Assembly .................................................................................................... Brush Inspection ............................................................................................................... Commutator Cleaning and Inspection............................................................................... Armature Inspection.......................................................................................................... Brush Lead Inspection ...................................................................................................... Brush Plate and Terminal Bolt Inspection .........................................................................
16-4 16-10 16-11 16-12 16-14 16-16 16-17 16-17 16-18 16-18 16-18 16-19 16-22 16-22 16-22 16-23 16-24 16-24 16-24 16-25 16-25 16-25 16-26 16-28 16-28 16-30 16-33 16-33 16-33 16-33 16-34 16-34 16-35 16-35 16-36 16-36 16-36 16-37 16-37 16-38 16-41 16-41 16-41 16-42 16-42 16-43 16-43 16-44 16-44 16-44
16
16-2 ELECTRICAL SYSTEM Starter Relay Inspection.................................................................................................... Lighting System ...................................................................................................................... Headlight Beam Horizontal Adjustment ............................................................................ Headlight Beam Vertical Adjustment................................................................................. Headlight Bulb Replacement ............................................................................................ Headlight Removal/Installation ......................................................................................... City Light Bulb Replacement............................................................................................. Tail/Brake Light Bulb Replacement ................................................................................... Tail/Brake Light Removal .................................................................................................. Tail/Brake Light Installation ............................................................................................... License Plate Light Bulb Replacement ............................................................................. Turn Signal Light Bulb Replacement ................................................................................ Turn Signal Relay Inspection ............................................................................................ Air Switching Valve ................................................................................................................. Air Switching Valve Operation Test ................................................................................... Air Switching Valve Unit Test ............................................................................................ Radiator Fan System.............................................................................................................. Fan Motor Inspection ........................................................................................................ Resistor Inspection ........................................................................................................... Meter, Gauge, Indicator Unit................................................................................................... Meter Unit Removal/Installation ........................................................................................ Meter Unit Disassembly .................................................................................................... Meter, Indicator Light Bulb Replacement .......................................................................... Tachometer Inspection...................................................................................................... Water Temperature Gauge Inspection .............................................................................. Switches and Sensors ............................................................................................................ Brake Light Timing Inspection........................................................................................... Brake Light Timing Adjustment ......................................................................................... Switch Inspection .............................................................................................................. Water Temperature Sensor Inspection ............................................................................. Speed Sensor Removal .................................................................................................... Speed Sensor Installation ................................................................................................. Speed Sensor Inspection.................................................................................................. Oxygen Sensor Removal ................................................................................................. Oxygen Sensor Installation .............................................................................................. Oxygen Sensor Inspection ............................................................................................... Fuel Reserve Switch Inspection........................................................................................ Relay Box ............................................................................................................................... Relay Box Removal .......................................................................................................... Relay Circuit Inspection .................................................................................................... Diode Circuit Inspection .................................................................................................... Fuse........................................................................................................................................ 30 A Main Fuse Removal.................................................................................................. Fuse Box Fuse Removal................................................................................................... 15 A ECU Fuse Removal.................................................................................................. Fuse Installation................................................................................................................ Fuse Inspection.................................................................................................................
16-44 16-47 16-47 16-47 16-47 16-48 16-48 16-49 16-50 16-50 16-50 16-51 16-52 16-54 16-54 16-54 16-56 16-56 16-56 16-58 16-58 16-58 16-59 16-59 16-60 16-62 16-62 16-62 16-62 16-63 16-63 16-64 16-64 16-64 16-65 16-65 16-65 16-66 16-66 16-66 16-67 16-69 16-69 16-69 16-69 16-70 16-70
ELECTRICAL SYSTEM 16-3 Dummy Page
16-4 ELECTRICAL SYSTEM Exploded View
ELECTRICAL SYSTEM 16-5 Exploded View No. 1 2 3 4 5
Fastener Front Brake Light Switch Screw License Plate Light Cover Screws License Plate Light Mounting Screws Switch Housing Screws Tail/Brake Light Mounting Bolts
N·m 1.2 0.90 1.2 3.5 5.9
Torque kgf·m 0.12 0.092 0.12 0.36 0.60
ft·lb 11 in·lb 8.0 in·lb 11 in·lb 31 in·lb 52 in·lb
Remarks
16-6 ELECTRICAL SYSTEM Exploded View
ELECTRICAL SYSTEM 16-7 Exploded View No.
Fastener
1 2 3
Alternator Cover Bolts Alternator Rotor Bolt Crankshaft Sensor Screws
4
Plugs (Alternator Cover)
5 6 7 8 9 10 11 12 13 14
Regulator/Rectifier Bolts Spark Plugs Speed Sensor Bolt Starter Motor Cable Terminal Nut Starter Motor Clutch Bolts Starter Motor Mounting Bolts Starter Motor Terminal Locknut Starter Motor Through Bolts Starter Relay Cable Terminal Nuts Stator Coil Bolts
G: Apply grease. L: Apply a non-permanent locking agent. M: Apply molybdenum disulfide grease. R: Replacement Parts S: Follow the specified tightening sequence. SS: Apply silicone sealant.
N·m 9.8 88.2 3.0
Torque kgf·m 1.0 9.0 0.31
ft·lb 87 in·lb 65 27 in·lb
–
–
–
9.8 13 7.8 9.8 34.3 9.8 6.9 3.4 5.0 12
1.0 1.3 0.80 1.0 3.5 1.0 0.70 0.35 0.51 1.2
87 in·lb 115 in·lb 69 in·lb 87 in·lb 25 87 in·lb 61 in·lb 30 in·lb 44 in·lb 106 in·lb
Remarks
S Hand -Tighten
L L
16-8 ELECTRICAL SYSTEM Exploded View
ELECTRICAL SYSTEM 16-9 Exploded View No. 1 2 3 4 5 6 7 8
Fastener Fuel Pump Bolts Neutral Switch Oil Pressure Switch Oil Pressure Switch Terminal Bolt Oxygen Sensor Resistor Bolt Sidestand Switch Bolt Water Temperature Sensor
G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts SS: Apply silicone sealant.
N·m 9.8 15 15 1.5 44.1 7.8 8.8 25
Torque kgf·m 1.0 1.5 1.5 0.15 4.50 0.80 0.90 2.5
ft·lb 87 in·lb 11 11 13 in·lb 32.5 69 in·lb 78 in·lb 18
Remarks L SS G
L
16-10 ELECTRICAL SYSTEM Specifications Item Battery Type Model Name Capacity Voltage Charging System Type Alternator Output Voltage Stator Coil Resistance Charging Voltage (Regulator/Rectifier Output Voltage) Ignition System Crankshaft Sensor Resistance Crankshaft Sensor Peak Voltage Stick Coil: Primary Winding Resistance Secondary Winding Resistance Primary Peak Voltage Spark Plug: Type Gap Electric Starter System Starter Motor: Brush Length Commutator Diameter Air Switching Valve Resistance Switches and Sensors Rear Brake Light Switch Timing Engine Oil Pressure Switch Connections Water Temperature Sensor Resistance
Standard Sealed Battery YTX9-BS 12 V 8 Ah 12.8 V or more Three-phase AC 40 V or more at 4 000 r/min (rpm) 0.05 ∼ 0.6 Ω at 20°C (68°F) 13.9 ∼ 14.9 V
100 ∼ 150 Ω 4.5 V or more 1.0 ∼ 1.6 Ω 10.8 ∼ 16.2 kΩ 90 V or more NGK CR8E 0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.)
10 mm (0.39 in.) (Service Limit: 5.0 mm (0.20 in.)) 28 mm (1.10 in.) (Service Limit: 27 mm (1.06 in.)) 20 ∼ 24 Ω at 20°C (68°F) ON after about 10 mm (0.39 in.) of pedal travel When engine is stopped: ON When engine is running: OFF In the text
ELECTRICAL SYSTEM 16-11 Special Tools and Sealant Flywheel Holder: 57001-1313
Peak Voltage Adapter: 57001-1415
Hand Tester: 57001-1394
Lead Wire - Peak Voltage Adapter: 57001-1449
Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5: 57001-1405
Kawasaki Bond (Silicone Sealant): 92104-0004
16-12 ELECTRICAL SYSTEM Parts Location
ELECTRICAL SYSTEM 16-13 Parts Location 1. Meter Unit 2. Ignition Switch 3. Starter Lockout Switch 4. Air Switching Valve 5. Stick Coils 6. Spark Plugs 7. Starter Relay 8. Relay Box 9. ECU 10. Turn Signal Relay 11. Fuse Box 12. Battery 12 V 8 Ah 13. Speed Sensor 14. Sidestand Switch 15. Neutral Switch 16. Starter Motor 17. Alternator 18. Crankshaft Sensor 19. Oil Pressure Switch 20. Regulator/Rectifier 21. Front Brake Light Switch 22. Resistor 23. Fan Motor 24. Water Temperature Sensor 25. Oxygen Sensor 26. Engine Ground 27. Rear Brake Light Switch
16-14 ELECTRICAL SYSTEM Wiring Diagram
ELECTRICAL SYSTEM 16-15 Wiring Diagram
16-16 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and observe all the rules below. ○Do not reverse the battery cable connections. This will burn out the diodes on the electrical parts. ○Always check battery condition before condemning other parts of an electrical system. A fully charged battery is a must for conducting accurate electrical system tests. ○The electrical parts should never be struck sharply, as with a hammer, or allowed to fall on a hard surface. Such a shock to the parts can damage them. ○To prevent damage to electrical parts, do not disconnect the battery cables or any other electrical connections when the ignition switch is ON, or while the engine is running. ○Because of the large amount of current, never keep the starter button pushed when the starter motor will not turn over, or the current may burn out the starter motor windings. ○Take care not to short the cables that are directly connected to the battery positive (+) terminal to the chassis ground. ○Troubles may involve one or in some cases all items. Never replace a defective part without determining what CAUSED the failure. If the failure was caused by some other item or items, they must be repaired or replaced, or the new replacement will soon fail again. ○Make sure all connectors in the circuit are clean and tight, and examine wires for signs of burning, fraying, etc. Poor wires and bad connections will affect electrical system operation. ○Measure coil and winding resistance when the part is cold (at room temperature).
ELECTRICAL SYSTEM 16-17 Electrical Wiring Wiring Inspection
inspect the wiring for signs of burning, fraying, • Visually etc. If any wiring is poor, replace the damaged wiring. Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. Check the wiring for continuity. ○Use the wiring diagram to find the ends of the lead which is suspected of being a problem. ○Connect the hand tester between the ends of the leads.
• •
Special Tool - Hand Tester: 57001-1394
○Set the tester to the × 1 Ω range, and read the tester.
If the tester does not read 0 Ω, the lead is defective. Replace the lead or the wiring harness [B] if necessary.
16-18 ELECTRICAL SYSTEM Battery Battery Removal
off the ignition switch. • Turn Remove: • Front Seat (see Front Seat Removal in the Frame chapter) Relay Box (see Relay Box Removal) Screw [A] and Battery Cover [B]
• Disconnect the negative (–) cable [A]. CAUTION
Be sure to disconnect the negative (–) cable first. out the positive (+) terminal cap [B] and disconnect • Slide the positive (+) cable. • Remove the battery [C].
• Remove the screws [A] and battery case [B] as necessary.
Battery Installation
off the ignition switch. • Turn Put the into the battery case. • Connectbattery positive (+) cable [A] first. • Connect the the (–) cable [B]. • Apply a light negative coat of grease on the terminals to prevent • corrosion. • Cover the (+) terminal with red cap [C]. the projections [A] into the holes [B]. • Insert Install the removed parts (see appropriate chapters). •
ELECTRICAL SYSTEM 16-19 Battery Battery Activation Electrolyte Filling Make sure that the model name [A] of the electrolyte container matches the model name [B] of the battery. These names must be the same.
•
Battery Model Name for EX250K: YTX9-BS
CAUTION Be sure to use the electrolyte container with the same model name as the battery since the electrolyte volume and specific gravity vary with the battery type. This is to prevent overfilling of the electrolyte, shorting the battery life, and deterioration of the battery performance.
CAUTION Do not remove the aluminum sealing sheet [A] from the filler ports [B] until just prior to use. Be sure to use the dedicated electrolyte container for correct electrolyte volume. the battery on a level surface. • Place Check • or holestoinseeit. that the sealing sheet has no peeling, tears, • Remove the sealing sheet.
NOTE
○The battery is vacuum sealed. If the sealing sheet has leaked air into the battery, it may require a longer initial charge. the electrolyte container from the vinyl bag. • Remove the strip of caps [A] from the container and set • Detach aside, these will be used later to seal the battery.
NOTE
○Do not pierce or otherwise open the sealed cells [B] of the electrolyte container. Do not attempt to separate individual cells.
the electrolyte container upside down with the six • Place sealed cells into the filler ports of the battery. Hold the container level, push down to break the seals of all six cells. You will see air bubbles rising into each cell as the ports fill.
NOTE
○Do not tilt the electrolyte container.
16-20 ELECTRICAL SYSTEM Battery the electrolyte flow. • Check If no air bubbles [A] are coming up from the filler ports, or
•
if the container cells have not emptied completely, tap the container [B] a few times. Keep the container in place for 20 minutes or more. Don’t remove the container from the battery until it’s empty, the battery requires all the electrolyte from the container for proper operation.
CAUTION Removal of the container before it is completely empty can shorten the service life of the battery. Do not remove the electrolyte container until it is completely empty and 20 minutes have elapsed. remove the container from the battery. • Gently Let the battery sit for 30 minutes prior to charging to allow • the electrolyte to permeate into the plates for optimum performance.
○Charging
NOTE
the battery immediately after filling can shorten service life. Let the battery sit for at least 30 minutes after filling.
Initial Charge Place the strip [A] of caps loosely over the filler ports. Newly activated sealed batteries require an initial charge.
• •
Standard Charge: 0.9 A × 5 ∼ 10 hours
If using a recommended battery charger, follow the charger’s instructions for newly activated sealed battery. Kawasaki-recommended chargers: Optimate III Yuasa 1.5 Amp Automatic Charger Battery Mate 150-9
If the above chargers are not available, use equivalent one.
NOTE
○Charging rates will vary depending on how long the battery has been stored, temperature, and the type of charger used. Let battery sit 30 minutes after initial charge, then check voltage using a voltmeter. If it is not at least 12.8 V, repeat charging cycle.
ELECTRICAL SYSTEM 16-21 Battery charging is completed, press down firmly with both • After hands to seat the strip of caps [A] into the battery (don’t pound or hammer). When properly installed, the strip of the caps will be level with the top of the battery.
CAUTION Once the strip of the caps is installed onto the battery, never remove the caps, nor add water or electrolyte to the battery.
NOTE
○To ensure maximum battery life and customer satisfaction, it is recommended the battery be load tested at three times its amp-hour rating for 15 seconds. Re-check voltage and if less than 12.8 V repeat the charging cycle and load test. If still below 12.8 V the battery is defective.
16-22 ELECTRICAL SYSTEM Battery Precautions 1) No need of topping-up No topping-up is necessary in this battery until it ends its life under normal use. Forcibly prying off the seal cap to add water is very dangerous. Never do that. 2) Refreshing charge If an engine will not start, a horn sounds weak, or lamps are dim, it indicates the battery has been discharged. Give refresh charge for 5 to 10 hours with charge current shown in the specification (see Refreshing Charge). When a fast charge is inevitably required, do it following precisely the maximum charge current and time conditions indicated on the battery.
CAUTION This battery is designed to sustain no unusual deterioration if refresh-charged according to the method specified above. However, the battery’s performance may be reduced noticeably if charged under conditions other than given above. Never remove the seal cap during refresh charge. If by chance an excessive amount of gas is generated due to overcharging, the relief valve releases the gas to keep the battery normal. 3) When you do not use the motorcycle for months. Give a refresh charge before you store the motorcycle and store it with the negative cable removed. Give a refresh charge once a month during storage. 4) Battery life If the battery will not start the engine even after several refresh charges, the battery has exceeded its useful life. Replace it (Provided, however, the vehicle’s starting system has no problem).
WARNING Keep the battery away from sparks and open flames during charging, since the battery gives off an explosive gas mixture of hydrogen and oxygen. When using a battery charger, connect the battery to the charger before turning on the charger. This procedure prevents sparks at the battery terminals which could ignite any battery gases. No fire should be drawn near the battery, or no terminals should have the tightening loosened. The electrolyte contains sulfuric acid. Be careful not to have it touch your skin or eyes. If touched, wash it off with liberal amount of water. Get medial attention if severe.
Interchange A sealed battery can fully display its performance only when combined with a proper vehicle electric system. Therefore, replace a sealed battery only on a motorcycle which was originally equipped with a sealed battery. Be careful, if a sealed battery is installed on a motorcycle which had an ordinary battery as original equipment, the sealed battery’s life will be shortened.
Charging Condition Inspection
○Battery charging condition can be checked by measuring
• •
battery terminal voltage with a digital voltmeter [A]. Remove the battery (see Battery Removal). Measure the battery terminal voltage.
NOTE
○Measure with a digital voltmeter which can be read one decimal place voltage.
ELECTRICAL SYSTEM 16-23 Battery If the reading is 12.8 V or more, no refresh charge is required, however, if the read is below the specified, refresh charge is required. Battery Terminal Voltage 12.8 V or more Standard:
Terminal Voltage (V) [A] Battery Charge Rate (%) [B] Good [C] Refresh charge is required [D]
Refreshing Charge
the battery [A] (see Battery Removal). • Remove Do refresh charge by following method according to the • battery terminal voltage.
WARNING This battery is sealed type. Never remove sealing cap [B] even at charging. Never add water. Charge with current and time as stated below.
Terminal Voltage: 11.5 ∼ less than 12.8 V Standard Charge 0.9 A × 5 ∼ 10 h (see following chart) Quick Charge
4A×1h
CAUTION If possible, do not quick charge. If quick charge is done unavoidably, do standard charge later on. Terminal Voltage: less than 11.5 V Charging Method: 0.9 A × 20 h
NOTE
○Increase the charging voltage to a maximum voltage of 25 V if the battery will not accept current initially. Charge for no more than 5 minutes at the increased voltage then check if the battery is drawing current. If the battery will accept current decrease the voltage and charge by the standard charging method described on the battery case. If the battery will not accept current after 5 minutes, replace the battery.
Battery [A] Battery Charger [B] Standard Value [C] Current starts to flow [D] the battery condition after refresh charge. •○Determine Determine the condition of the battery left for 30 minutes after completion of the charge by measuring the terminal voltage according to the table below. Criteria
Judgement
12.8 V or higher
Good
12.0 ∼ lower than 12.8 V
Charge insufficient → Recharge
lower than 12.0 V
Unserviceable → Replace
16-24 ELECTRICAL SYSTEM Charging System Alternator Cover Removal
• Remove: Left Lower Fairing (see Lower Fairing Removal in the Frame chapter) Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter) Water Pipes (see Water Pump Cover Removal in the Cooling System chapter) the alternator and crankshaft sensor lead con• Disconnect nectors [A].
a suitable container under the alternator cover [A]. • Place Take out • Remove: the leads from the clamps [B]. • Alternator Cover Bolts [C] Alternator Cover
Alternator Cover Installation
silicone sealant to the crankshaft sensor lead grom• Apply met and crankcase halves mating surface [A] on the front and rear sides of the cover mount. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004
that dowel pins [B] are in place on the crankcase. • Check a new gasket [C] and the alternator cover. • Install Tighten: •
Torque - Alternator Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
the leads correctly (see Cable, Wire, and Hose Rout• Run ing section in the Appendix chapter). • Install the removed parts (see appropriate chapters).
ELECTRICAL SYSTEM 16-25 Charging System Stator Coil Removal
• Remove: Alternator Cover (see Alternator Cover Removal) Screws [A] and Clamp [B] Crankshaft Sensor [C] Lead Grommets [D] Stator Coil Bolts [E] Stator Coil [F]
Stator Coil Installation
• Install the stator coil [A] and tighten the bolts.
Torque - Stator Coil Bolts: 12 N·m (1.2 kgf·m, 106 in·lb)
the alternator [B] and crankshaft sensor [C] leads • Install into the alternator cover as shown in the figure. Crankshaft Sensor [D] Damper [E] Clamp [F] Grommets [G] Silicone Sealant Applied Areas [H] ○Apply silicone sealant to the grommets, and fit them into the notch of the cover securely. Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004
the crankshaft sensor and clamp. • Install Tighten: •
Torque - Crankshaft Sensor Screws: 3.0 N·m (0.31 kgf·m, 27 in·lb)
the alternator cover (see Alternator Cover Installa• Install tion).
Alternator Rotor Removal
• Remove: Alternator Cover (see Alternator Cover Removal) Shaft [A] Starter Idle Gear [B]
the alternator rotor steady with the flywheel holder • Hold [A]. • Remove the rotor bolt [B] and washer [C]. Special Tool - Flywheel Holder: 57001-1313
CAUTION Do not hold the projections [D].
16-26 ELECTRICAL SYSTEM Charging System the flywheel puller [A], remove the alternator rotor • Using [B] from the crankshaft. Special Tool - Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5: 57001-1405
CAUTION Do not attempt to strike the alternator rotor itself. Striking the rotor can cause the magnets to lose their magnetism.
Alternator Rotor Installation
a cleaning fluid, clean off any oil or dirt on the fol• Using lowing portions and dry them with a clean cloth.
•
Crankshaft Tapered Portion [A] Alternator Rotor Tapered Portion [B] Apply a thin coat of molybdenum disulfide grease to the crankshaft [C].
the starter clutch gear [A] and washer [B]. • Install Again, • there. clean the crankshaft tapered portion [C] and dry the woodruff key [D] securely in the slot in the crank• Fit shaft before installing the alternator rotor.
the alternator rotor [A] while turning [B] the starter • Install clutch gear [C].
ELECTRICAL SYSTEM 16-27 Charging System
• Install the washer and alternator rotor bolt [A]. NOTE
○Confirm the alternator rotor fit or not to the crankshaft before tightening it with specified torque.
the rotor bolt and tighten it with 55 N·m (5.6 kgf·m, • Install 41 ft·lb) of torque. Special Tool - Flywheel Holder [B]: 57001-1313
CAUTION Do not hold the projections [C]. the rotor bolt and washer. • Remove Check the tightening torque with flywheel puller. •
Special Tool - Flywheel Puller Assembly, M38 × 1.5/M35 × 1.5: 57001-1405
•
If the rotor is not pulled out with 20 N·m (2.0 kgf·m, 15 ft·lb) of drawing torque, it is installed correctly. If the rotor is pulled out with under 20 N·m (2.0 kgf·m, 15 ft·lb) of drawing torque, clean off any oil dirt or flaw of the crankshaft and rotor tapered portion, and dry them with a clean cloth. Then, confirm that it is not pulled out with above torque. Tighten the alternator rotor bolt while holding the alternator rotor steady with the flywheel holder. Special Tool - Flywheel Holder: 57001-1313
CAUTION Do not hold the projections. Torque - Alternator Rotor Bolt: 88.2 N·m (9.0 kgf·m, 65 ft·lb)
a thin coat of molybdenum disulfide grease to the • Apply shaft [A], and install it and starter idle gear [B]. the alternator cover (see Alternator Cover Installa• Install tion).
16-28 ELECTRICAL SYSTEM Charging System Charging Voltage Inspection
the battery condition (see Charging Condition In• Check spection). up the engine to obtain actual alternator operating • Warm conditions. the battery cover (see Battery Removal). • Remove Check that the ignition switch is turned off, and connect • the hand tester [A] to the battery terminals [B]. Special Tool - Hand Tester: 57001-1394
the engine, and note the voltage readings at var• Start ious engine speeds with the headlight turned on and then turned off (To turn off the headlight, disconnect the headlight connector on the headlight unit.). The readings should show nearly battery voltage when the engine speed is low, and, as the engine speed rises, the readings should also rise. But they must be kept under the specified voltage. Charging Voltage Tester Range 25 V DC
Connections Tester (+) to
Tester (–) to
Battery (+)
Battery (–)
Reading 13.9 ∼ 14.9 V
off the ignition switch to stop the engine, and discon• Turn nect the hand tester. If the charging voltage is kept between the values given in the table, the charging system is considered to be working normally. If the charging voltage is much higher than the values specified in the table, the regulator/rectifier is defective or the regulator/rectifier leads are loose or open. If the charging voltage does not rise as the engine speed increases, then the regulator/rectifier is defective or the alternator output is insufficient for the loads. Check the alternator and regulator/rectifier to determine which part is defective.
Alternator Inspection There are three types of alternator failures: short, open (wire burned out), or loss in rotor magnetism. A short or open in one of the coil wires will result in either a low output, or no output at all. A loss in rotor magnetism, which may be caused by dropping or hitting the alternator, by leaving it near an electromagnetic field, or just by aging, will result in low output.
ELECTRICAL SYSTEM 16-29 Charging System check the alternator output voltage, do the following • To procedures.
○Turn off the ignition switch. ○Remove the right side cover (see Side Cover Removal in the Frame chapter).
○Disconnect the alternator lead connector [A]. ○Connect the hand tester as shown in the table 1. Special Tool - Hand Tester: 57001-1394
○Start the engine. ○Run it at the rpm given in the table 1. ○Note the voltage readings (total 3 measurements). Table 1 Alternator Output Voltage Tester Range 250 V AC
at 4 000 r/min (rpm)
Connections Tester (+) to One Yellow Lead
Tester (–) to Another Yellow Lead
Reading 40 V or more
If the output voltage shows the value in the table, the alternator operates properly. The regulator/rectifier is damaged. If the output voltage shows a much lower reading than that given in the table, stop the engine and inspect the stator coil resistance. Check the stator coil resistance as follows. ○Stop the engine. ○Connect the hand tester as shown in the table 2.
•
Special Tool - Hand Tester: 57001-1394
○Note the readings (total 3 measurements). Table 2 Stator Coil Resistance Tester Range
Connections Tester (+) to
Tester (–) to
× 1 Ω One Yellow Lead Another Yellow Lead
•
at 20°C (68°F) Reading 0.05 ∼ 0.6 Ω
If there is more resistance than shown in the table, or no hand tester reading (infinity) for any two leads, the stator has an open lead and must be replaced. Much less than this resistance means the stator is shorted, and must be replaced. Using the highest resistance range of the hand tester, measure the resistance between each of the yellow leads and chassis ground. Any hand tester reading less than infinity (∞) indicates a short, necessitating stator replacement. If the stator coils have normal resistance, but the voltage check showed the alternator to be defective; then the rotor magnets have probably weakened, and the rotor must be replaced.
16-30 ELECTRICAL SYSTEM Charging System Regulator/Rectifier Inspection
• Remove: Left Lower Fairing (see Lower Fairing Removal in the Frame chapter) Bolts [A] Connector [B] (Disconnect) Regulator/Rectifier [C]
Rectifier Circuit Check Check conductivity of the following pair of terminals.
•
Rectifier Circuit Inspection Tester connection
W-Y1,
W-Y2,
W-Y3
BK/Y-Y1,
BK/Y-Y2,
BK/Y-Y3
The resistance should be low in one direction and more than ten times as much in the other direction. If any two terminals are low or high in both directions, the rectifier is defective and the regulator/rectifier must be replaced.
NOTE
○The actual meter reading varies with the meter used and the individual rectifier, but, generally speaking the lower reading should be from zero to one half the scale.
Regulator Circuit Check To test the regulator out of circuit, use three 12 V batteries and a test light (12 V 3 ∼ 6 W bulb in a socket with leads).
CAUTION The test light works as an indicator and also a current limiter to protect the regulator/rectifier from excessive current. Do not use an ammeter instead of a test light. to be sure the rectifier circuit is normal before con• Check tinuing. the 1st step regulator circuit test. •○Do Connect the test light and the 12 V battery to the regulator/rectifier as shown in the figure.
○Check the Y1, Y2 and Y3 terminal respectively.
If the test light turns on, the regulator/rectifier is defective. Replace it. If the test light does not turn on, continue the test.
ELECTRICAL SYSTEM 16-31 Charging System the 2nd step regulator circuit test. •○Do Connect the test light and the 12 V battery in the same manner as specified in the "Regulator Circuit Test-1st Step". ○Apply 12 V to the BR terminal. ○Check the Y1, Y2 and Y3 terminal respectively. If the test light turns on, the regulator/rectifier is defective. Replace it. If the test light does not turn on, continue the test.
the 3rd step regulator circuit test. •○Do Connect the test light and the 12 V battery in the same manner as specified in the "Regulator Circuit Test-1st Step". ○Momentarily apply 24 V to the BR terminal by adding a 12 V battery. ○Check the Y1, Y2 and Y3 terminals respectively.
CAUTION Do not apply more than 24 V. If more than 24 V is applied, the regulator/rectifier may be damaged. Do not apply 24 V more than a few seconds. If 24 V is applied for more than a few seconds, the regulator/rectifier may be damaged. If the test light did not light when the 24 V was applied momentarily to the voltage monitoring terminal, the regulator/rectifier is defective. Replace it. If the regulator/rectifier passes all of the tests described, it may still be defective. If the charging system still does not work properly after checking all of the components and the battery, test the regulator/rectifier by replacing it with a known good unit.
16-32 ELECTRICAL SYSTEM Charging System Charging System Circuit
1. Alternator 2. Battery 12 V 8 Ah 3. Frame Ground 4. Main Fuse 30 A 5. Joint Connector 1 6. Load 7. Water-proof Joint 3 8. Ignition Switch 9. Regulator/Rectifier
ELECTRICAL SYSTEM 16-33 Ignition System WARNING The ignition system produces extremely high voltage. Do not touch the spark plugs or stick coils while the engine is running, or you could receive a severe electrical shock.
CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch is ON, or while the engine is running. This is to prevent ECU damage. Do not install the battery backwards. The negative side is grounded. This is to prevent damage to the ECU.
Crankshaft Sensor Removal
• Refer to the Stator Coil Removal. Crankshaft Sensor Installation
• Refer to the Stator Coil Installation. Crankshaft Sensor Inspection
• Remove: Right Side Cover (see Side Cover Removal in the Frame •
chapter) Crankshaft Sensor Lead Connector [A] (Disconnect) Set the hand tester [B] to the × 1 Ω range and connect (+) lead to the yellow lead and (–) lead to the black lead in the connector. Special Tool - Hand Tester: 57001-1394 Crankshaft Sensor Resistance: 100 ∼ 150 Ω
•
If there is more resistance than the specified value, the coil has an open lead and must be replaced. Much less than this resistance means the coil is shorted, and must be replaced. Using the highest resistance range of the tester, measure the resistance between the crankshaft sensor leads and chassis ground. Any tester reading less than infinity (∞) indicates a short, necessitating replacement of the crankshaft sensor assembly.
16-34 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Peak Voltage Inspection NOTE
○Be sure the battery is fully charged.
• Remove: Right Side Cover (see Side Cover Removal in the Frame • •
chapter) Crankshaft Sensor Lead Connector [A] (Disconnect) Set the hand tester [B] to the DC 25 V range. Connect the peak voltage adapter [C] to the hand tester and crankshaft sensor leads in the connector. Special Tools - Hand Tester: 57001-1394 Peak Voltage Adapter: 57001-1415 Type: KEK-54-9-B Connections: Crankshaft Sensor Lead
Peak Voltage Adapter
Hand Tester
Yellow
←
Red
→
(+)
Black
←
Black
→
(–)
the ignition switch and engine stop switch ON. • Turn Pushing starter button, turn the engine 4 ∼ 5 sec• onds withthe the transmission gear in neutral to measure the
•
crankshaft sensor peak voltage. Repeat the measurement 5 or more times. Crankshaft Sensor Peak Voltage 4.5 V or more Standard:
If the tester reading is not specified one, inspect the crankshaft sensor (see Crankshaft Sensor Inspection).
Stick Coil Removal CAUTION Never drop the stick coils especially on a hard surface. Such a shock to the stick coils can damage it. the fuel tank (see Fuel Tank Removal in the Fuel • Remove System (DFI) chapter). the stick coil connectors [A]. • Disconnect Pull the stick coils [B] off the spark plugs. •
CAUTION
Do not pry the connector part of the coil while removing the coil.
ELECTRICAL SYSTEM 16-35 Ignition System Stick Coil Installation
the coil as shown being careful of the coil heads [A] • Insert direction. sure the stick coils are installed by pulling up it lightly. • Be Connect the connectors. •
CAUTION
Do not tap the coil head while installing the coil. the leads correctly (see Cable, Wire, and Hose Rout• Run ing section in the Appendix chapter). • Install the removed parts (see appropriate chapters).
Stick Coil Inspection
the stick coils (see Stick Coil Removal). • Remove Measure the primary winding resistance [A] as follows. •○Connect the hand tester between the coil terminals.
○Set the tester to the × 1 Ω range, and read the tester.
the secondary winding resistance [B] as follows. •○Measure Connect the tester between the plug terminal and (–) coil terminal. ○Set the tester to the × 1 kΩ range and read the tester. Stick Coil Winding Resistance Primary Windings: 1.0 ∼ 1.6 Ω Secondary Windings:
10.8 ∼ 16.2 kΩ
If the tester does not read as specified, replace the coil.
16-36 ELECTRICAL SYSTEM Ignition System Stick Coil Primary Peak Voltage NOTE
○Be sure the battery is fully charged. the stick coils (see Stick Coil Removal), but do • Remove not remove the spark plugs. the primary peak voltage as follows. •○Measure Install the new spark plug [A] into each stick coil [B], and ground them onto the engine.
○Connect the peak voltage adapter [C] into the hand tester
[D] which is set to the DC 250 V range. the adapter to the lead wire-peak voltage adapter [E] which is connected between the stick coil connector and stick coil. ECU [F] Battery [G]
○Connect
Special Tools - Hand Tester: 57001-1394 Peak Voltage Adapter: 57001-1415 Type: KEK-54-9-B Lead Wire - Peak Voltage Adapter: 57001 -1449 Primary Lead Connection Adapter (R, +) to lead wire-peak voltage adapter (R) Adapter (BK, –) to lead wire-peak voltage adapter (W)
WARNING To avoid extremely high voltage shocks, do not touch the spark plugs or tester connections. the ignition switch and the engine stop switch ON. • Turn the starter button, turn the engine 4 ∼ 5 seconds • Pushing with the transmission in neutral to measure the primary
•
peak voltage. Repeat the measurements 5 times for one stick coil. Stick Coil Primary Peak Voltage 90 V or more Standard:
the test for the other stick coil. • Repeat If the reading is less than the specified value, check the following. Stick Coils (see Stick Coil Inspection) Crankshaft Sensor (see Crankshaft Sensor Inspection) ECU (see ECU Power Supply Inspection in the Fuel System (DFI) chapter)
Spark Plug Removal
to the Spark Plug Replacement in the Periodic • Refer Maintenance chapter.
Spark Plug Installation
to the Spark Plug Replacement in the Periodic • Refer Maintenance chapter.
ELECTRICAL SYSTEM 16-37 Ignition System Spark Plug Condition Inspection
the spark plugs (see Spark Plug Replacement in • Remove the Periodic Maintenance chapter). inspect the spark plugs. • Visually If the spark plug center electrode [A] and/or side elec-
•
trode [B] are corroded or damaged, or if the insulator [C] is cracked, replace the plug. If the spark plug is dirtied or the carbon is accumulated, replace the spark plug. Measure the gap [D] with a wire-type thickness gauge. If the gap is incorrect, replace the spark plug. Spark Plug Gap:
0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.)
• Use the standard spark plug or its equivalent. Spark Plug:
NGK CR8E
Interlock Operation Inspection
the rear wheel off the ground with stand. • Raise Turn the •1st Check engine stop switch ON (run position). • Start the engine to the following conditions. Condition: Transmission Gear → 1st Position Clutch Lever → Release Sidestand → Down or Up
○Turn the ignition switch ON and push the starter button. ○Then the starter motor should not turn when the starter
system circuit is normality. If the engine is start, inspect the starter lockout switch, neutral switch and relay box. If their parts are normality, replace the ECU.
2nd Check Start the engine to the following conditions.
•
Condition: Transmission Gear → 1st Position Clutch Lever → Pulled in Sidestand → Up
○Turn the ignition switch ON and push the starter button. ○Then the starter motor should turn when the starter sys-
tem circuit is normality. If the starter motor is not turn, inspect the starter lockout switch, neutral switch, sidestand switch and relay box. If their parts are normality, replace the ECU.
16-38 ELECTRICAL SYSTEM Ignition System 3rd Check Inspect the engine for its secure stop after the following operations are completed. Run the engine to the following conditions.
• •
Condition: Transmission Gear → 1st Position Clutch Lever → Pulled in Sidestand → Up
the sidestand on the ground, then the engine will stop. • Set If the engine does not stop, inspect the neutral switch, sidestand switch and relay box. If their parts are normality, replace the ECU.
IC Igniter Inspection
○The IC igniter is built in the ECU [A].
to the following items. • Refer Interlock Operation Inspection (see Interlock Operation Inspection) Ignition System Troubleshooting (see Ignition System section) ECU Power Supply Inspection (see ECU Power Supply Inspection in the Fuel System (DFI) chapter)
ELECTRICAL SYSTEM 16-39 Ignition System
16-40 ELECTRICAL SYSTEM Ignition System Ignition System Circuit
1. ECU 2. Joint Connector 2 3. Sidestand Switch 4. Battery 12 V 8 Ah 5. Frame Ground 6. Main Fuse 30 A 7. ECU Main Relay 8. Relay Box 9. Starter Lockout Switch 10. Ignition Fuse 10 A
11. ECU Fuse 15 A 12. Oxygen Sensor Heater Fuse 10 A 13. Fuse Box 14. Ignition Switch 15. Engine Stop Switch 16. Spark Plugs 17. Stick Coils 18. Water-proof Joint 3
19. Speed Sensor 20. Subthrottle Sensor 21. Main Throttle Sensor 22. Water-proof Joint 2 23. Vehicle-down Sensor 24. Water-proof Joint 1 25. Neutral Switch 26. Crankshaft Sensor 27. Oxygen Sensor
ELECTRICAL SYSTEM 16-41 Electric Starter System Starter Motor Removal CAUTION Do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. the lower fairings (see Lower Fairings Removal • Remove in the Frame chapter). back the rubber cap [A]. • Slide Remove: • Starter Motor Cable Terminal Nut [B] Mounting Bolts [C]
• Pull out the starter motor [A] toward the left side.
Starter Motor Installation CAUTION Do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. installing the starter motor, clean the starter mo• When tor legs [A] and crankcase [B] where the starter motor is grounded. the O-ring [A] with a new one. • Replace Apply grease • Tighten: to the O-ring. •
Torque - Starter Motor Mounting Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
• Install the starter motor cable, and tighten the nut.
Torque - Starter Motor Cable Terminal Nut: 9.8 N·m (1.0 kgf·m, 87 in·lb)
the rubber cap to the original position. • Slide Install the removed parts (see appropriate chapters). •
16-42 ELECTRICAL SYSTEM Electric Starter System Starter Motor Disassembly
the starter motor (see Starter Motor Removal). • Remove Take off the motor through bolts [A] and remove • the both endstarter covers [B] and pull the armature out of the yoke.
the terminal locknut [A], washer and insulators, • Remove and then remove the brushes and terminal bolt [B] with the brush plate [C] from the end cover.
Starter Motor Assembly
the O-rings with new ones. • Replace Apply a thin coat of high-temperature grease to the oil seal • [A] and needle bearing [B]. Fit the toothed washer [C] into the end cover. •
• Install: Brush Plate [A] •
New O-ring Insulators Washer Tighten: Torque - Starter Motor Terminal Locknut [B]: 6.9 N·m (0.70 kgf·m, 61 in·lb)
○Fit the tongue [C] of the brush plate into the groove of the end cover.
the steel washer [A] and resin washer [B] on the • Install armature shaft. • Install the armature [C] among the brushes.
ELECTRICAL SYSTEM 16-43 Electric Starter System
• Align the end covers [A] with the marks [C] of the yoke [B].
the O-rings on the through bolts with new ones • Replace and tighten them. Torque - Starter Motor Through Bolts: 3.4 N·m (0.35 kgf·m, 30 in·lb)
Brush Inspection
the length of each brush [A]. • Measure If any is worn down to the service limit, replace the brush plate assembly [B]. Starter Motor Brush Length [C] Standard: 10 mm (0.39 in.) Service Limit:
5.0 mm (0.20 in.)
Commutator Cleaning and Inspection
the commutator surface [A] if necessary with fine • Smooth emery cloth [B], and clean out the grooves.
the diameter [A] of the commutator [B]. • Measure If the commutator diameter is less than the service limit, replace the starter motor with a new one. Commutator Diameter Standard: 28 mm (1.10 in.) Service Limit:
27 mm (1.06 in.)
16-44 ELECTRICAL SYSTEM Electric Starter System Armature Inspection
Using the × 1 Ω hand tester range, measure the resis• tance between any two commutator segments [A]. Special Tool - Hand Tester: 57001-1394
•
If there is a high resistance or no reading (∞) between any two segments, a winding is open and the starter motor must be replaced. Using the highest hand tester range, measure the resistance between the segments and the shaft [B]. If there is any reading at all, the armature has a short and the starter motor must be replaced.
NOTE
○Even if the foregoing checks show the armature to be
good, it may be defective in some manner not readily detectable with the hand tester. If all other starter motor and starter motor circuit components check good, but the starter motor still does not turn over or only turns over weakly, replace the starter motor with a new one.
Brush Lead Inspection
Using the × 1 Ω hand tester range, measure the resis• tance as shown in the figure. Terminal Bolt and Positive Brush [A] Brush Plate and Negative Brush [B] Special Tool - Hand Tester: 57001-1394
If there is not close to zero ohms, the brush lead has an open. Replace the brush plate assembly.
Brush Plate and Terminal Bolt Inspection
the highest hand tester range, measure the resis• Using tance as shown in the figure. Terminal Bolt and Brush Plate [A] Terminal Bolt and Negative Brush Holder [B] Terminal Bolt and End Cover [C] Special Tool - Hand Tester: 57001-1394
If there is any reading, the brush holder and/or terminal bolt have a short. Replace the brush plate assembly.
Starter Relay Inspection
• Remove: Battery Negative (–) Cable (see Battery Removal) Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Bracket Bolts [A] Bracket [B]
ELECTRICAL SYSTEM 16-45 Electric Starter System
• Remove: Cable Terminals [A] and Connector [B] (Disconnect) Starter Relay [C]
the hand tester [A] and 12 V battery [B] to the • Connect starter relay [C] as shown in the figure. Special Tool - Hand Tester: 57001-1394
If the relay does not work as specified, the relay is defective. Replace the relay. Testing Relay Tester Range: Criteria:
× 1 Ω range When battery is connected → 0 Ω When battery is disconnected → ∞ Ω
16-46 ELECTRICAL SYSTEM Electric Starter System Electric Starter Circuit
1. Ignition Switch 2. Engine Stop Switch 3. Starter Button 4. Water-proof Joint 3 5. Neutral Switch 6. Joint Connector 2 7. Sidestand Switch 8. Battery 12 V 8 Ah 9. Frame Ground 10. Starter Relay 11. Main Fuse 30 A 12. Starter Motor 13. Relay Box 14. Starter Circuit Relay 15. Starter Lockout Switch 16. Fuse Box 17. Ignition Fuse 10 A
ELECTRICAL SYSTEM 16-47 Lighting System This motorcycle adopt the daylight system and have a headlight relay in the relay box. The headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on after the starter button is released and stays on until the ignition switch is turned off. The headlight will go out momentarily whenever the starter button is pressed and come back on when the button is released.
Headlight Beam Horizontal Adjustment
to the Headlight Aiming Inspection in the Periodic • Refer Maintenance chapter.
Headlight Beam Vertical Adjustment
to the Headlight Aiming Inspection in the Periodic • Refer Maintenance chapter.
Headlight Bulb Replacement
• Remove: Upper Fairing (see Upper Fairing Removal in the Frame chapter) Headlight Bulb Dust Cover [A]
• Remove: Hook [A] Headlight Bulb [B]
CAUTION When handling the quartz-halogen bulb, never touch the glass portion with bare hands. Always use a clean cloth. Oil contamination from hands or dirty rags can reduce bulb life or cause the bulb to explode.
NOTE
○Clean off any contamination that inadvertently gets on the bulb with alcohol or soap and water solution.
the headlight bulb. • Replace Fit the projection [A] of the bulb in the hollow [B] of the • headlight.
16-48 ELECTRICAL SYSTEM Lighting System
• Install the hook [A].
the dust cover [A] onto the bulb [B] firmly as shown in • Fit the figure.
•
Good [C] Bad [D] After installation, adjust the headlight aim (see Headlight Aiming Inspection in the Periodic Maintenance chapter).
Headlight Removal/Installation
to the Upper Fairing Disassembly/Assembly in the • Refer Frame chapter. installing, confirm the damper [A] between the head• After light [B] and upper fairing [C] as shown in the figure.
City Light Bulb Replacement
the upper fairing (see Upper Fairing Removal in • Remove the Frame chapter). • Pull out the socket [A] together with the bulb.
ELECTRICAL SYSTEM 16-49 Lighting System
• Pull out the bulb [A] straight from the socket. CAUTION
Do not turn the bulb. Pull the bulb out to prevent damage to the bulb. Do not use bulb rated for greater wattage then the specified value.
• Replace the bulb with a new one. Tail/Brake Light Bulb Replacement
the rear seat (see Rear Seat Removal in the • Remove Frame chapter). • Turn the socket [A] counterclockwise [B].
the bulb [A] in the socket, turn it counterclockwise • Push [B], and pull it out.
the new bulb [A] by aligning its upper and lower pins • Insert [B] with the upper and lower grooves [C] in the socket, and turn the bulb clockwise. ○Turn the bulb about 15°.
the projections [A] of the socket into the grooves [B] of • Fit the tail/brake light. • Turn the socket clockwise.
16-50 ELECTRICAL SYSTEM Lighting System Tail/Brake Light Removal
• Remove: Seat Covers (see Seat Cover Removal in the Frame chapter) Connector [A] (Disconnect) Tail/Brake Light Mounting Bolts [B] Tail/Brake Light [C]
Tail/Brake Light Installation
• Tighten:
Torque - Tail/Brake Light Mounting Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb)
the lead correctly (see Cable, Wire, and Hose Rout• Run ing section in the Appendix chapter).
License Plate Light Bulb Replacement
• Remove: Screws [A]
License Plate Light Cover [B]
and turn the bulb [A] counterclockwise and remove • Push it. • Replace the bulb with a new one.
the new bulb [A] by aligning its upper and lower pins • Insert [B] with the upper and lower grooves [C] in the socket, and turn the bulb clockwise. ○Turn the bulb about 15°. Tighten:
•
Torque - License Plate Light Cover Screws: (0.092 kgf·m, 8.0 in·lb)
0.90 N·m
ELECTRICAL SYSTEM 16-51 Lighting System Headlight/Tail Light Circuit
1. High Beam Indicator Light 12 V 3.4 W 2. Ignition Switch 3. Alternator 4. Water-proof Joint 3 5. Joint Connector 2 6. License Plate Light 12 V5W
7. Tail/Brake Light 12 V 21/5 W 8. Battery 12 V 8 Ah 9. Frame Ground 10. Starter Relay 11. Main Fuse 30 A 12. Headlight Circuit Relay 13. Relay Box 14. Taillight Fuse 10 A
Turn Signal Light Bulb Replacement
• Unscrew the screw [A] and remove the lens [B].
15. Headlight Fuse 10 A 16. Fuse Box 17. Dimmer Switch 18. Headlight (Low) 12 V 55 W 19. Headlight (High) 12 V 55 W 20. City Light 12 V 5 W 21. Joint Connector 1
16-52 ELECTRICAL SYSTEM Lighting System and turn the bulb [A] counterclockwise and remove • Push it.
the new bulb [A] by aligning its upper and lower pins • Insert [B] with the upper and lower grooves [C] in the socket, and turn the bulb clockwise. ○Turn the bulb about 15°.
Turn Signal Relay Inspection
• Remove: Left Seat Cover (see Seat Cover Removal in the Frame chapter) Turn Signal Relay [A] Connector [B] (Disconnect)
one 12 V battery and turn signal lights as indi• Connect cated in the figure, and count how may times the lights flash for one minute. Turn Signal Relay [A] Turn Signal Lights [B] 12 V Battery [C] If the lights do not flash as specified, replace the turn signal relay. Testing Turn Signal Relay Load The Number of Turn Signal Lights
Wattage (W)
Flashing Times (c/m*)
1**
10
Lights stays on
2
20
75 ∼ 95
(*): Cycle(s) per minute (**): Corrected to "one light burned out".
ELECTRICAL SYSTEM 16-53 Lighting System Turn Signal Light Circuit
1. Ignition Switch 2. Water-proof Joint 3 3. Joint Connector 2 4. Rear Right Turn Signal Light 12 V 10 W 5. Rear Left Turn Signal Light 12 V 10 W 6. Battery 12 V 8 Ah 7. Frame Ground 8. Main Fuse 30 A 9. Turn Signal Relay Fuse 10 A 10. Fuse Box 11. Turn Signal Switch 12. Turn Signal Relay 13. Front Left Turn Signal Light 12 V 10 W 14. Front Right Turn Signal Light 12 V 10 W 15. Joint Connector 1 16. Turn Signal Indicator Light 12 V 3.4 W
16-54 ELECTRICAL SYSTEM Air Switching Valve Air Switching Valve Operation Test
to the Air Suction System Damage Inspection in the • Refer Periodic Maintenance chapter.
Air Switching Valve Unit Test
the air switching valve (see Air Switching Valve • Remove Removal in the Engine Top End chapter). tester [A] to the × 1 Ω range and connect it • toSetthetheairhand switching valve terminals as shown in the figure. Special Tool - Hand Tester: 57001-1394 Air Switching Valve Resistance Standard: 20 ∼ 24 Ω at 20°C (68°F)
If the tester does not read as specified value, replace it with a new one. the 12 V battery [A] to the air switching valve • Connect terminals as shown in the figure.
the air to the inlet air duct [A], and make sure does • Blow not flow the blown air from the outlet air duct [B].
the 12 V battery. • Disconnect the air to the inlet air duct [A] again, and make sure • Blow flow the blown air from the outlet air duct [B]. If the air switching valve does not operate as described, replace it with a new one.
NOTE
○To check air flow through the air switching valve, just blow through the air switching valve hose (inlet side).
ELECTRICAL SYSTEM 16-55 Air Switching Valve Air Switching Valve Circuit
1. ECU 2. Joint Connector 2 3. Battery 12 V 8 Ah 4. Frame Ground 5. Main Fuse 30 A 6. Relay Box 7. ECU Main Relay 8. ECU Fuse 15 A 9. Fuse Box 10. Ignition Switch 11. Water-proof Joint 3 12. Air Switching Valve
16-56 ELECTRICAL SYSTEM Radiator Fan System Fan Motor Inspection
the fuel tank (see Fuel Tank Removal in the Fuel • Remove System (DFI) chapter). the connector [A]. • Disconnect Using an auxiliary leads, supply battery power to the fan • motor. If the fan does not rotate, the fan motor is defective and must be replaced.
Resistor Inspection
• Remove: Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Bolt [A] Clamp [B] Connectors [C] Resistor [D]
the hand tester to the × 1 Ω range, and check the • Set continuity as shown in the figure. Special Tools - Hand Tester: 57001-1394 Connections:
BL lead [A] ←→ BL lead [B] BK lead [C] ←→ BK lead [D]
Standard
About 0 Ω
If the resistor has an open or short, replace it with a new one.
ELECTRICAL SYSTEM 16-57 Radiator Fan System Radiator Fan Circuit
1. ECU 2. Joint Connector 2 3. Battery 12 V 8 Ah 4. Frame Ground 5. Main Fuse 30 A 6. Joint Connector 1 7. Relay Box 8. Fan Relay 9. ECU Fuse 15 A 10. Fan Fuse 10 A 11. Fuse Box 12. Resistor 13. Fan Motor 14. Water-proof Joint 3 15. Water-proof Joint 1 16. Water Temperature Sensor
16-58 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit Meter Unit Removal/Installation
• Remove: Upper Fairing (see Upper Fairing Removal in the Frame chapter) Speedometer Cable Upper End [A] Connectors [B]
• Remove the inner cover [A] with meter unit [B].
• Remove: Bolts [A] Meter Unit [B]
CAUTION Place the meter unit so that the face is up. If a meter unit is left upside down or sideways for any length of time, it will malfunction.
is the reverse of removal. •○Installation Fit the projections [A] into the grommets [B]. the leads and cable correctly (see Cable, Wire, and • Run Hose Routing section in the Appendix chapter). • Install the removed parts (see appropriate chapters).
Meter Unit Disassembly
• Remove: Meter Unit (Meter Unit Removal/Installation) Screws [A] Meter Cover [B]
ELECTRICAL SYSTEM 16-59 Meter, Gauge, Indicator Unit the speedometer [A], tachometer [B] and water • Remove temperature gauge [C] by removing screws [D].
CAUTION Do not remove a meter pointer unless the meter is to be replace. The pointers cannot be reinstalled. The pointer mounting is different from replacement meters.
Meter, Indicator Light Bulb Replacement
the meter unit (Meter Unit Removal/Installation). • Remove Pull out the [A] together with the bulb. • Pull the bulbsocket [B] out of the socket. •
CAUTION
Do not turn the bulb. Pull the bulb out to prevent damage to the bulb. Do not use bulb rated for greater wattage then the specified value. the bulb with a new one. •○Replace Repeat the same procedure for other bulbs.
Tachometer Inspection
the meter unit (see Meter Unit Removal/Installa• Remove tion). the insulated auxiliary leads, connect the 12 V bat• Using tery to the meter unit connector (9 pins connector) as follows.
○Connect the battery positive terminal to the BR lead ter-
minal [A]. ○Connect the battery negative terminal to the BK/Y lead terminal [B].
CAUTION Do not short each terminals. the insulated auxiliary leads, open and connect the • Using BK lead terminal [A] to the battery positive terminal repeatedly.
16-60 ELECTRICAL SYSTEM Meter, Gauge, Indicator Unit the tachometer needle [A] should flick [B]. • Then If the needle does not flick, check the meter unit harness for continuity (see wiring diagram in this section). Special Tool - Hand Tester: 57001-1394
If the harness is normal, replace the tachometer.
Water Temperature Gauge Inspection
the meter unit (see Meter Unit Removal/Installa• Remove tion). the insulated auxiliary leads, connect the 12 V bat• Using tery to the meter unit connector (9 pins connector) as follows.
○Connect the battery positive terminal to the BR lead terminal [A]. ○Connect the battery negative terminal to the BK/Y lead terminal [B].
CAUTION Do not short each terminals. the variable rheostat [A] to the W/Y lead terminal • Connect [B] as shown in the figure. • Adjust the resistance value to the approximately 20 Ω.
water temperature gauge [A] indicate the position [B] • The of the about 125°C. If the water temperature gauge does not work, check the meter unit harness for continuity (see wiring diagram in this section). Special Tool - Hand Tester: 57001-1394
If the harness is normal, replace the water temperature gauge.
ELECTRICAL SYSTEM 16-61 Meter, Gauge, Indicator Unit Meter Unit Circuit
1. Fuel Level Warning Indicator Light 12 V 3.4 W 2. Ignition Switch 3. Water-proof Joint 3 4. Water Temperature Sensor 5. Neutral Switch 6. Oil Pressure Switch 7. ECU 8. Fuel Reserve Switch 9. Battery 12 V 8 Ah 10. Frame Ground 11. Main Fuse 30 A 12. Fuse Box
13. Ignition Fuse 10 A 14. Joint Connector 1 15. FI Indicator Light 12 V 3.4 W 16. Oil Pressure Warning Indicator Light 12 V 3.4 W 17. Neutral Indicator Light 12 V 3.4 W 18. Turn Signal Indicator Light 12 V 3.4 W 19. High Beam Indicator Light 12 V 3.4 W 20. Tachometer 21. Speedometer 22. Water Temperature Gauge 23. Meter Lights 12 V 3.4 W
16-62 ELECTRICAL SYSTEM Switches and Sensors Brake Light Timing Inspection
to the Brake Light Switch Operation Inspection in • Refer the Periodic Maintenance chapter.
Brake Light Timing Adjustment
to the Brake Light Switch Operation Inspection in • Refer the Periodic Maintenance chapter.
Switch Inspection
a hand tester, check to see that only the connec• Using tions shown in the table have continuity.
○For the switch housings and the ignition switch, refer to the tables in the Wiring Diagram. If the switch has an open or short, repair it or replace it with a new one. Special Tool - Hand Tester: 57001-1394 Rear Brake Light Switch Connections
Sidestand Switch Connections
Neutral Switch Connections
Oil Pressure Switch Connections*
*: Engine lubrication system is in good condition.
ELECTRICAL SYSTEM 16-63 Switches and Sensors Water Temperature Sensor Inspection
the water temperature sensor (see Water Tem• Remove perature Sensor Removal/Installation in the Fuel System
• •
(DFI) chapter). Suspend the sensor [A] in a container of coolant so that the threaded portion is submerged. Suspend an accurate thermometer [B] with temperature sensing portions [C] located in almost the same depth.
NOTE
○The sensor and thermometer must not touch the container side or bottom. the container over a source of heat and gradu• Place ally raise the temperature of the coolant while stirring the coolant gently. Using the hand tester, measure the internal resistance of the sensor. ○The sensor sends electric signals to the ECU and water temperature gauge in the meter unit. ○Measure the resistance across the terminals and the body (for the gauge) at the temperatures shown in the table. If the hand tester does not show the specified values, replace the sensor.
•
Water Temperature Sensor Resistance for ECU [D] Resistance (kΩ)
Temperature
(Terminal [1]-[3]) + 0.155
20°C (68°F)
2.46
80°C (176°F)
0.32 ±0.011
110°C (230°F)
0.1426 ±0.0041
– 0.143
Resistance for Water Temperature Gauge [E] Resistance (Ω)
Temperature
(Terminal [2]-Body)
50°C (122°F)
210 ±40
120°C (248°F)
21.2 ±1.5
Speed Sensor Removal CAUTION Never drop the sensor especially on a hard surface. Such a shock to the sensor can damage it.
• Remove: Left Side Cover (see Side Cover Removal in the Frame chapter) Engine Sprocket Cover (see Engine Sprocket Removal in the Final Drive chapter) Connector [A] (Disconnect)
16-64 ELECTRICAL SYSTEM Switches and Sensors
• Remove: Speed Sensor Bolt [A] Speed Sensor [B]
Speed Sensor Installation
is the reverse of removal. • Installation Run the lead (see Cable, Wire, and Hose Rout• ing section in correctly the Appendix chapter). a non-permanent locking agent to the threads of • Apply the speed sensor bolt, and tighten it. Torque - Speed Sensor Bolt: 7.8 N·m (0.80 kgf·m, 69 in·lb)
• Install the removed parts (see appropriate chapters). Speed Sensor Inspection
the speed sensor (see Speed Sensor Removal). • Remove the speed sensor connector [A] with the battery • Connect [B], 10 kΩ resistor [C] and hand tester [D] as shown in the
•
figure. Set the tester to the DC 25 V range. Special Tool - Hand Tester: 57001-1394
[A] each side of the speed sensor surface with the • Trace screwdriver.
○Then the tester indicator should flick [B].
If the tester indicator does not flick, replace the speed sensor.
Oxygen Sensor Removal CAUTION Never drop the sensor especially on a hard surface. Such a shock to the sensor can damage it.
• Remove: Right Lower Fairing (see Lower Fairing Removal in the • •
Frame chapter) Oxygen Sensor Lead Connector [A] (Disconnect) Free the lead from the clamps [B]. Remove the oxygen sensor [C].
ELECTRICAL SYSTEM 16-65 Switches and Sensors Oxygen Sensor Installation CAUTION Never drop the oxygen sensor [A] especially on a hard surface. Such a shock to the unit can damage it. Do not touch the sensing part [B] and filter holes [C] of the sensor to prevent oil contact. Oil contamination from hands can reduce sensor performance.
• Tighten:
Torque - Oxygen Sensor: 44.1 N·m (4.50 kgf·m, 32.5 ft·lb)
the oxygen sensor lead correctly (see Cable, Wire, • Run and Hose Routing section in the Appendix chapter).
Oxygen Sensor Inspection
to the Oxygen Sensor Inspection in the Fuel System • Refer (DFI) chapter.
Fuel Reserve Switch Inspection
the fuel tank (see Fuel Tank Removal in the Fuel • Remove System (DFI) chapter). the fuel tank with fuel. • Fill Close cap surely. • Connectthethefueltesttank light [A] (12 V 3.4 W bulb in a socket with • leads) and the 12 V battery [B] to the fuel pump connector. Connections: Battery (+) → 12 V 3.4 W Bulb (One Side) 12 V 3.4 W Bulb (Other Side) → BL Lead Terminal Battery (–) → BK Lead Terminal
If the test light turn on, the reserve switch is defective. Replace the fuel pump. the fuel pump (see Fuel Pump Removal in the • Remove Fuel System (DFI) chapter). the test light (12 V 3.4 W bulb in a socket with • Connect leads) and the 12 V battery to the fuel pump connector as shown in the figure. 12 V Battery [A] Test Light [B] Fuel Pump Connector [C] Fuel Reserve Switch [D] If the test light doesn’t light, replace the fuel pump.
NOTE
○It may take a long time to turn on the test light in case that the fuel reserve switch is inspected just after the fuel pump is removed. Leave the fuel reserve switch with leads for inspection connected for few minutes.
16-66 ELECTRICAL SYSTEM Relay Box The relay box [A] has relays and diodes. The relays and diodes can not be removed.
Relay Box Removal CAUTION Never drop the relay box especially on a hard surface. Such a shock to the relay box can damage it.
• Remove: Front Seat (see Front Seat Removal in the Frame chapter) Connectors [A] (Disconnect) Relay Box [B]
Relay Circuit Inspection
the relay box (see Relay Box Removal). • Remove Check conductivity of the following numbered terminals • by connecting the hand tester and one 12 V battery to the relay box as shown in the figure (see Relay Box Internal Circuit in this section). If the tester does not read as specified, replace the relay box. Relay Circuit Inspection (with the battery disconnected) Headlight Circuit Relay ECU Main Relay Fuel Pump Relay Starter Circuit Relay Fan Relay
Tester Connection
Tester Reading (Ω)
1-3
∞
7-6
∞
4-5
Not ∞*
7-8
∞
9-10
Not ∞*
11-16
∞
11-12
∞
17-20
∞
18-19
Not ∞*
*: The actual reading varies with the hand tester used.
ELECTRICAL SYSTEM 16-67 Relay Box Relay Circuit Inspection (with the battery connected) Battery Connection (+) (–)
Tester Connection
Tester Reading (Ω)
2-11
1-3
0
4-5
7-6
0
ECU Main Relay Fuel Pump Relay
9-10
7-8
0
Fan Relay
18-19
17-20
0
Battery Connection (+) (–)
Tester Connection DC 25 V Range (+) (–)
Tester Reading (V)
16-12
11-12
Battery Voltage
Starter Circuit Relay
(+): Apply positive lead. (–): Apply negative lead.
Diode Circuit Inspection
the relay box (see Relay Box Removal). • Remove conductivity of the following pairs of terminals (see • Check Relay Box Internal Circuit in this section). Diode Circuit Inspection Tester Connection
1-11, 2-11, 12-13, 12-15, 12-16, 13-14, 13-15
The resistance should be low in one direction and more than ten times as much in the other direction. If any diode shows low or high in both directions, the diode is defective and the relay box must be replaced.
NOTE
○The actual meter reading varies with the meter or tester
used and the individual diodes, but generally speaking, the lower reading should be from zero to one half the scale.
16-68 ELECTRICAL SYSTEM Relay Box Relay Box Internal Circuit
A: Headlight Circuit Relay B: ECU Main Relay C: Fuel Pump Relay D: Starter Circuit Relay E: Fan Relay
ELECTRICAL SYSTEM 16-69 Fuse 30 A Main Fuse Removal
• Remove: Front Seat (see Front Seat Removal in the Frame chapter) 30 A Main Fuse Connector [A] (Disconnect)
out the main fuse [A] from the starter relay with a • Pull needle nose pliers.
Fuse Box Fuse Removal
the front seat (see Front Seat Removal in the • Remove Frame chapter). • Unlock the hook [A] to lift up the lid [B].
the fuses [A] straight out of the fuse box with needle • Pull nose pliers.
15 A ECU Fuse Removal
the front seat (see Front Seat Removal in the • Remove Frame chapter). • Unlock the hook [A] to lift up the lid [B].
16-70 ELECTRICAL SYSTEM Fuse
• Pull out the ECU fuse [A] from the fuse box.
Fuse Installation
fails during operation, inspect the electrical sys• Iftema fuse to determine the cause, and then replace it with a
•
new fuse of proper amperage. Install the fuse box fuses on the original position as specified on the lid.
Fuse Inspection
the fuse (see 30 A Main/Fuse Box/15 A ECU • Remove Fuse Removal). the fuse element. • Inspect If it is blown out, replace the fuse. Before replacing a blown fuse, always check the amperage in the affected circuit. If the amperage is equal to or greater than the fuse rating, check the wiring and related components for a short circuit. Housing [A] Fuse Element [B] Terminals [C] Blown Element [D]
CAUTION When replacing a fuse, be sure the new fuse matches the specified fuse rating for that circuit. Installation of a fuse with a higher rating may cause damage to wiring and components.
APPENDIX 17-1
Appendix Table of Contents Cable, Wire, and Hose Routing .............................................................................................. Troubleshooting Guide ...........................................................................................................
17-2 17-32
17
17-2 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-3 Cable, Wire, and Hose Routing 1. Headlight (High) Connector 2. Headlight (Low) Connector 3. Bands 4. Meter Lead Connectors 5. City Light Lead Connector 6. Horn Lead Connectors 7. Regulator/Rectifier Lead Connector 8. Oil Pressure Switch Lead Connector 9. Left Switch Housing Lead Connectors 10. Inlet Air Pressure Sensor Lead Connector 11. Stick Coil #1 Lead Connector 12. Front Left Turn Signal Light Lead Connector 13. Fuel Injector #1 Lead Connector 14. Subthrottle Valve Actuator Lead Connector 15. Neutral Switch Lead Connector 16. Sidestand Switch Lead Connector 17. Speed Sensor Lead Connector 18. Inlet Air Temperature Sensor Lead Connector 19. Fuel Pump Lead Connector 20. Starter Relay Lead Connector 21. Relay Box Lead Connectors 22. Turn Signal Relay Lead Connector 23. Clamp 24. Fuse Box 25. Clamp 26. Band
17-4 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-5 Cable, Wire, and Hose Routing 1. License Plate Light Lead Connector 2. Tail/Brake Light Lead Connector 3. ECU Lead Connectors 4. Rear Brake Light Switch Lead Connector 5. Rear Right Turn Signal Light Lead Connector 6. Rear Left Turn Signal Light Lead Connector 7. Kawasaki Diagnostic System Connector 8. Bands 9. Battery Negative Cable 10. Alternator Lead Connector 11. Crankshaft Sensor Lead Connector 12. Fuel Injector #2 Lead Connector 13. Front Right Turn Signal Light Lead Connector 14. Subthrottle Sensor Lead Connector 15. Main Throttle Sensor Lead Connector 16. Oxygen Sensor Lead Connector 17. Stick Coil #1 Lead Connector 18. Ignition Switch Lead Connector 19. Air Switching Valve Lead Connector 20. Frame Ground Terminal 21. Vehicle-down Sensor Lead Connector 22. Right Switch Housing Lead Connector 23. Resistor Lead Connector
17-6 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-7 Cable, Wire, and Hose Routing 1. Right Switch Housing Lead 2. Guide (Run the left switch housing lead through into the guide.) 3. Guide (Run the right switch housing lead through into the guide.) 4. Clutch Cable 5. Left Switch Housing Lead 6. Guide (Run the clutch cable and left switch housing lead through into the guide.) 7. Guide (Run the throttle cables, right switch housing and ignition switch leads through into the guide.) 8. Brake Hose 9. Throttle Cable (Accelerator) 10. Throttle Cable (Decelerator) 11. Ignition Switch Lead 12. Speedometer Cable 13. Guide (Run the speedometer cable through into the guide.) 14. Guide (Run the speedometer cable through into the guide.) 15. Guides (Run the main harness through into the guides.) 16. Regulator/Rectifier Lead Connector 17. Left Switch Housing Lead Connector 18. Guide (Run the throttle cables and inlet air pressure sensor lead through into the guide.) 19. Guides (Run the main harness through inside the guides.) 20. Inlet Air Pressure Sensor Lead Connector 21. Guide (Run the horn lead through into the guide.) 22. Horn Lead Connectors 23. Guide (Run the main harness through inside the guide.) 24. Band (Hold the main harness together with the frame pipe.) 25. Clamp (Hold the main harness and insert the clamp into the frame.)
17-8 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-9 Cable, Wire, and Hose Routing 1. Speedometer Cable 2. Guide (Run the headlight (high) lead through into the guide.) 3. Headlight (High) Connector 4. Band (Hold the headlight (high) lead and insert the band into the upper fairing bracket.) 5. Guide (Run the meter unit harness and main harness through into the guide.) 6. Band (Hold the meter unit harness and main harness, and insert the band into the upper fairing bracket.) 7. Starter Lockout Switch Lead 8. Meter Connectors 9. Left Switch Housing Lead 10. Headlight (Low) Connector 11. Fuel Tank Breather Hose 12. Guide (Run the fuel tank breather hose through into the guide.) 13. Guide (Run the fuel tank breather hose through into the guide.) 14. Guide (Run the fuel tank breather and reserve tank overflow hoses through into the guide.) 15. Guide (Run the fuel tank breather and reserve tank overflow hoses through into the guide.) 16. Run the fuel tank breather and reserve tank overflow hoses through the inside of the swingarm. 17. Reserve Tank Overflow Hose 18. Sidestand Switch Lead Connector 19. Clamp (Run the sidestand switch lead through the inside of the clamp.) 20. Sidestand Switch
17-10 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-11 Cable, Wire, and Hose Routing 1. Ignition Switch Lead Connector 2. Vehicle-down Sensor Lead Connector 3. Throttle Cable (Accelerator) 4. Throttle Cable (Decelerator) 5. Guide (Run the throttle cables, right switch housing and ignition switch leads through into the guide.) 6. Right Switch Housing Lead 7. Brake Hose 8. Clamp 9. Clutch Cable 10. Air Switching Valve Lead Connector 11. Band (Hold the main harness and insert the band into the frame.) 12. Resistor Lead Connector (Main Harness Side) 13. Right Switch Housing Lead Connector 14. Clamp (Hold the right switch housing and resistor leads, and insert the clamp into the frame.) 15. Resistor Lead Connector (Radiator Fan Side) 16. Water Temperature Sensor Lead Connector 17. Resistor 18. Bracket
17-12 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-13 Cable, Wire, and Hose Routing 1. Subthrottle Sensor Lead Connector 2. Main Throttle Sensor Lead Connector 3. Front Right Turn Signal Light Lead Connector 4. Oxygen Sensor 5. Clutch Cable 6. Subthrottle Sensor 7. Main Throttle Sensor 8. Fuel Injector #2 9. Subthrottle Valve Actuator Lead Connector 10. Fuel Injector #1 11. Throttle Body Assy 12. Fuel Injector #2 Lead Connector 13. Fuel Injector #1 Lead Connector
17-14 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-15 Cable, Wire, and Hose Routing 1. Stick Coil #1 Lead Connector 2. Front Left Turn Signal Light Lead Connector 3. Throttle Cable (Decelerator) 4. Throttle Cable (Accelerator) 5. Guide (Run the oil pressure switch lead through into the guide.) 6. Oil Pressure Switch Lead Connector 7. Stick Coil #2 Lead Connector 8. Inlet Air Temperature Sensor Lead Connector 9. To Fuel Tank 10. Fuel Pump Lead Connector
17-16 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-17 Cable, Wire, and Hose Routing 1. Clamp (Hold the neutral switch and speed sensor leads.) 2. Speed Sensor Lead 3. Neutral Switch Lead Connector 4. Insert the speed sensor lead into the groove of the speed sensor mounting bracket. 5. Clutch Cable 6. Clamps (Hold the oxygen sensor lead.) 7. Oxygen Sensor Lead Connector
17-18 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-19 Cable, Wire, and Hose Routing 1. Alternator Lead Connector 2. Crankshaft Sensor Lead Connector 3. Alternator Lead 4. Crankshaft Sensor Lead 5. Brackets 6. Clutch Cable 7. Run the clutch cable and reserve tank hose into the hole of the reserve tank. 8. Reserve Tank Overflow Hose 9. Reserve Tank Hose 10. Battery Negative Cable (Set the direction of the cable as shown in the figure.)
17-20 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-21 Cable, Wire, and Hose Routing 1. Starter Relay 2. Relay Box Lead Connectors 3. Clamp (Hold the main harness and insert the clamp into the frame.) 4. ECU Lead Connectors 5. Battery Positive Cable 6. Clamp (Hold the main harness and insert the clamp into the frame.) 7. Turn Signal Relay Lead Connector 8. Clamp (Hold the rear turn signal light and turn signal relay leads, and insert the clamp into the rear fender.) 9. Rear Turn Signal Light Lead Connectors 10. Rear Brake Light Switch 11. Clamp (Hold the rear brake light switch lead.) 12. Rear Brake Light Switch Lead Connector 13. Battery Negative Cable 14. Starter Motor Cable
17-22 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-23 Cable, Wire, and Hose Routing 1. Tail/Brake Light Lead Connector 2. License Plate Light Lead Connector 3. Clamp (Hold the license plate light lead.) 4. Clamp (Hold the license plate light and tail/brake light leads.) 5. Rear Right Turn Signal Light Lead 6. Rear Left Turn Signal Light Lead 7. License Plate Light Lead 8. Clamp 9. Kawasaki Diagnostic System Connector 10. Self-diagnosis Terminal
17-24 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-25 Cable, Wire, and Hose Routing 1. Thermostat 2. Radiator Cap 3. Install the hose so that its white paint mark side faces the radiator. 4. Radiator 5. Clamp Screw 6. 45° 7. Cylinder Head 8. 45 ∼ 55° 9. Align the white paint mark on the hose with the projection mark on the fitting. 10. Install the hose so that its end covers the white paint mark on the pipe. 11. Cylinder 12. Install the hose so that its white paint mark side faces the pipe. 13. Align the white paint mark on the hose with the projection mark on the fitting. 14. Upper 15. Viewed A 16. Section B-B 17. Viewed C 18. Viewed D
17-26 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-27 Cable, Wire, and Hose Routing 1. Run the reserve tank overflow hose into the guides. 2. Reserve Tank Overflow Hose 3. Bracket 4. Run the clutch cable and reserve tank hose into the hole of the reserve tank. 5. Clutch Cable 6. Reserve Tank Hose 7. Radiator Cap 8. Reserve Tank 9. Clamps 10. Hose Curve Side 11. Run the only reserve tank overflow hose into the bracket guide.
17-28 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-29 Cable, Wire, and Hose Routing 1. Vehicle-down Sensor 2. Clamps 3. Air Switching Valve 4. Install the hose so that its white mark side faces the air switching valve. 5. Damper 6. Inlet Air Pressure Sensor 7. Vacuum Hose 8. Air Switching Valve Hose 9. Clamp
17-30 APPENDIX Cable, Wire, and Hose Routing
APPENDIX 17-31 Cable, Wire, and Hose Routing 1. Front Master Cylinder 2. Front Brake Hose 3. Bracket 4. Guide 5. Front Brake Caliper 6. Rear Brake Reservoir Tank 7. Rear Brake Caliper 8. Clamp 9. Rear Master Cylinder
17-32 APPENDIX Troubleshooting Guide NOTE
○Refer to the Fuel System chapter for most
of DFI trouble shooting guide. ○This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties.
Engine Doesn’t Start, Starting Difficulty: Starter motor not rotating: Ignition and engine stop switch not ON Starter lockout switch or neutral switch trouble Starter motor trouble Battery voltage low Starter relay not contacting or operating Starter button not contacting Starter system wiring shorted or open Ignition switch trouble Engine stop switch trouble Main 30 A or ignition fuse blown Starter motor rotating but engine doesn’t turn over: Vehicle-down sensor (DFI) coming off Starter clutch trouble Starter idle gear trouble Engine won’t turn over: Valve seizure Valve lifter seizure Cylinder, piston seizure Crankshaft seizure Connecting rod small end seizure Connecting rod big end seizure Transmission gear or bearing seizure Camshaft seizure Starter idle gear seizure No fuel flow: No fuel in tank Fuel pump trouble Fuel tank air vent obstructed Fuel filter clogged Fuel line clogged No spark; spark weak: Vehicle-down sensor (DFI) coming off Ignition switch not ON Engine stop switch turned OFF Clutch lever not pulled in or gear not in neutral Battery voltage low Spark plug dirty, broken, or gap maladjusted Spark plug incorrect Stick coil shorted or not in good contact Stick coil trouble ECU trouble
Neutral, starter lockout, or sidestand switch trouble Crankshaft sensor trouble Ignition switch or engine stop switch shorted Starter system wiring shorted or open Main 30 A or ignition fuse blown Fuel/air mixture incorrect: Bypass screw and/or idle adjusting screw maladjusted Air passage clogged Air cleaner clogged, poorly sealed, or missing Leak from oil filler cap, crankcase breather hose or air cleaner drain cap. Compression Low: Spark plug loose Cylinder head not sufficiently tightened down Cylinder, piston worn Piston ring bad (worn, weak, broken, or sticking) Piston ring/groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak No valve clearance Valve not seating properly (valve bent, worn, or carbon accumulation on the seating surface)
Poor Running at Low Speed: Spark weak: Battery voltage low Stick coil trouble Stick coil shorted or not in good contact Spark plug dirty, broken, or maladjusted Spark plug incorrect ECU trouble Crankshaft sensor trouble Fuel/air mixture incorrect: Bypass screw maladjusted Air passage clogged Air bleed pipe bleed holes clogged Pilot passage clogged Air cleaner clogged, poorly sealed, or missing Fuel tank air vent obstructed Fuel pump trouble Throttle body assy holder loose Air cleaner duct loose Compression low: Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder, piston worn
APPENDIX 17-33 Troubleshooting Guide Piston ring bad (worn, weak, broken, or sticking) Piston ring/groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly (valve bent, worn, or carbon accumulation on the seating surface) Camshaft cam worn Run-on (dieseling): Ignition switch trouble Engine stop switch trouble Fuel injector trouble Loosen terminal of battery (–) cable or ECU ground lead Carbon accumulating on valve seating surface Engine overheating Other: ECU trouble Throttle body assy not synchronizing Engine oil viscosity too high Drive train trouble Brake dragging Clutch slipping Engine overheating Air suction valve trouble Air switching valve trouble
Poor Running or No Power at High Speed: Firing incorrect: Spark plug dirty, broken, or maladjusted Spark plug incorrect Stick coil shorted or not in good contact trouble Stick coil trouble ECU trouble Fuel/air mixture incorrect: Air cleaner clogged, poorly sealed, or missing Air cleaner duct loose Water or foreign matter in fuel Throttle body assy holder loose Fuel to injector insufficient Fuel tank air vent obstructed Fuel line clogged Fuel pump trouble Compression low: Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder, piston worn Piston ring bad (worn, weak, broken, or sticking)
Piston ring/groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly (valve bent, worn, or carbon accumulation on the seating surface) Knocking: Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect ECU trouble Miscellaneous: Throttle valve won’t fully open Brake dragging Clutch slipping Engine overheating Engine oil level too high Engine oil viscosity too high Drive train trouble Camshaft cam worn Air suction valve trouble Air switching valve trouble Catalytic converter melt down due to muffler overheating (KLEEN)
Overheating: Firing incorrect: Spark plug dirty, broken, or maladjusted Spark plug incorrect ECU trouble Muffler overheating: For KLEEN, do not run the engine even if with only one cylinder misfiring or poor running (Request the nearest service facility to correct it) For KLEEN, do not push-start with a dead battery (Connect another full-charged battery with jumper cables, and start the engine using the electric starter) For KLEEN, do not start the engine under misfire due to spark plug fouling or poor connection of the stick coil For KLEEN, do not coast the motorcycle with the ignition switch off (Turn the ignition switch ON and run the engine) ECU trouble Fuel/air mixture incorrect: Throttle body assy holder loose Air cleaner duct loose Air cleaner clogged, poorly sealed, or missing Compression high: Carbon built up in combustion chamber Engine load faulty: Clutch slipping Engine oil level too high
17-34 APPENDIX Troubleshooting Guide Engine oil viscosity too high Drive train trouble Brake dragging Lubrication inadequate: Engine oil level too low Engine oil poor quality or incorrect Gauge incorrect: Water temperature gauge broken Water temperature sensor broken Coolant incorrect: Coolant level too low Coolant deteriorated Wrong coolant mixed ratio Cooling system component incorrect: Radiator fin damaged Radiator clogged Thermostat trouble Radiator cap trouble Radiator fan relay trouble Fan motor broken Fan blade damaged Water pump not turning Water pump impeller damaged
Over Cooling: Gauge incorrect: Water temperature gauge broken Water temperature sensor broken Cooling system component incorrect: Thermostat trouble
Clutch Operation Faulty: Clutch slipping: Friction plate worn or warped Steel plate worn or warped Clutch spring broken or weak Clutch hub or housing unevenly worn No clutch lever play Clutch inner cable trouble Clutch release mechanism trouble Clutch not disengaging properly: Clutch plate warped or too rough Clutch spring compression uneven Engine oil deteriorated Engine oil viscosity too high Engine oil level too high Clutch housing frozen on drive shaft Clutch hub nut loose Clutch hub spline damaged Clutch friction plate installed wrong Clutch lever play excessive Clutch release mechanism trouble
Gear Shifting Faulty: Doesn’t go into gear; shift pedal doesn’t return: Clutch not disengaging Shift fork bent or seized Gear stuck on the shaft Shift return spring weak or broken Shift return spring pin loose Shift mechanism arm broken Shift pawl broken Pawl spring broken Jumps out of gear: Shift fork ear worn, bent Gear groove worn Gear dogs and/or dog holes worn Shift drum groove worn Shift fork guide pin worn Drive shaft, output shaft, and/or gear splines worn Overshifts: Neutral positioning pin spring weak or broken Pawl spring broken
Abnormal Engine Noise: Knocking: ECU trouble Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Overheating Piston slap: Cylinder/piston clearance excessive Cylinder, piston worn Connecting rod bent Piston pin, piston pin hole worn Valve noise: Valve clearance incorrect Valve spring broken or weak Camshaft bearing worn Valve lifter worn Other noise: Connecting rod small end clearance excessive Connecting rod big end clearance excessive Piston ring/groove clearance excessive Piston ring worn, broken, or stuck Piston ring groove worn Piston seizure, damage Cylinder head gasket leaking Exhaust pipe leaking at cylinder head connection Crankshaft runout excessive Engine mount loose Crankshaft bearing worn Primary gear worn or chipped
APPENDIX 17-35 Troubleshooting Guide Camshaft chain tensioner trouble Camshaft chain, sprocket, guide worn Air suction valve damaged Air switching valve damaged Alternator rotor loose Catalytic converter melt down due to muffler overheating (KLEEN)
Abnormal Drive Train Noise: Clutch noise: Clutch damper weak or damaged Clutch housing/friction plate clearance excessive Clutch housing gear worn Transmission noise: Bearings worn Transmission gear worn or chipped Metal chips jammed in gear teeth Engine oil insufficient Drive line noise: Drive chain adjusted improperly Drive chain worn Rear and/or engine sprocket worn Chain lubrication insufficient Rear wheel misaligned
Abnormal Frame Noise: Front fork noise: Oil insufficient or too thin Spring weak or broken Rear shock absorber noise: Shock absorber damaged Disc brake noise: Pad installed incorrectly Pad surface glazed Disc warped Caliper trouble Other noise: Bracket, nut, bolt, etc. not properly mounted or tightened
Oil Pressure Warning Indicator Light Goes On: Engine oil pump damaged Engine oil screen clogged Engine oil filter clogged Engine oil level too low Engine oil viscosity too low Camshaft bearing worn Crankshaft bearing worn Oil pressure switch damaged Wiring faulty Relief valve stuck open O-ring at the oil passage in the crankcase damaged
Exhaust Smokes Excessively: White smoke: Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Engine oil level too high Black smoke: Air cleaner clogged Brown smoke: Air cleaner duct loose Air cleaner poorly sealed or missing
Handling and/or Stability Unsatisfactory: Handlebar hard to turn: Cable routing incorrect Hose routing incorrect Wiring routing incorrect Steering stem nut too tight Steering stem bearing damaged Steering stem bearing lubrication inadequate Steering stem bent Tire air pressure too low Handlebar shakes or excessively vibrates: Tire worn Swingarm pivot bearing worn Rim warped, or not balanced Wheel bearing worn Handlebar mounting bolt loose Steering stem nut loose Front, rear axle runout excessive Engine mounting nut loose Handlebar pulls to one side: Frame bent Wheel misalignment Swingarm bent or twisted Swingarm pivot shaft runout excessive Steering maladjusted Front fork bent Right and left front fork oil level uneven Shock absorption unsatisfactory: (Too hard) Front fork oil excessive Front fork oil viscosity too high Rear shock absorber adjustment too hard Tire air pressure too high Front fork bent (Too soft) Tire air pressure too low Front fork oil insufficient and/or leaking Front fork oil viscosity too low Rear shock adjustment too soft Front fork, rear shock absorber spring weak Rear shock absorber oil leaking
17-36 APPENDIX Troubleshooting Guide Brake Doesn’t Hold: Air in the brake line Pad or disc worn Brake fluid leakage Disc warped Contaminated pad Brake fluid deteriorated Primary or secondary cup damaged in master cylinder Master cylinder scratched inside
Battery Trouble: Battery discharged: Charge insufficient Battery faulty (too low terminal voltage) Battery cable making poor contact Load excessive (e.g., bulb of excessive wattage) Ignition switch trouble Alternator trouble Wiring faulty Regulator/rectifier trouble Battery overcharged: Alternator trouble Regulator/rectifier trouble Battery faulty
MODEL APPLICATION Year 2008
Model EX250K8F
Beginning Frame No. JKAEX250KKDA00052
□:This digit in the frame number changes from one machine to another.
Part No.99924-1399-01
Printed in Japan
